Fuel Cap Tester (SST008)

FUEL CAP TESTER

TECHNICAL SERVICE BULLETIN

SUBJECT

This bulletin provides information relating to a Fuel Cap Tester provided to all KMA retailers as a mandatory Special Service Tool (SST). The Fuel Cap Tester must be used to test all original equipment and genuine replacement Kia fuel caps prior to replacement under warranty.

Fig 1: Identifying Fuel Cap Tester

SERVICE PROCEDURE

1. Remove the fuel cap from the vehicle.
2. Allow any fuel remaining on the cap to evaporate.
3. If the cap gasket is dirty, clean the gasket before testing the cap. Replace the fuel cap if the gasket is damaged.
4. Select the correct cap adapter:
   • Black adapter - for threaded type fuel cap
   • Brown adapter - for newer style Kia fuel cap used on some 2004 and later models.
     Fig 2: Connecting Adapter To Quick Disconnect Fitting On Tester

     
5. Connect the adapter to the quick disconnect fitting on the tester.
   NOTE: Do not connect the fuel cap to the adapter at this time.
6. Power up the tester using the "PRESS TO START" button (item #1 in illustration). All LEDs will light for a short duration. The tester will perform an auto-zero function; the green "PASS" LED (item #3 in illustration) will illuminate during this function. The red LED (item #2 in illustration) will illuminate when the tester is ready.
Fig 3: Identifying Components Of Tester

7. Install the fuel cap onto the adapter, and tighten the fuel cap until it clicks three (3) times.
   NOTE: If cap testing is not started within 20 seconds after the auto-zero function is complete, the tester will shut down. If this occurs, remove the fuel cap from the adapter, then restart the procedure from Step  6.
8. Pump the handle of the fuel cap tester until the green "STOP" LED (item #4 in illustration) illuminates. If the cap cannot be pressurized, the tester will "time out" and the "OBDII FAIL" LED (item #2 in illustration) will flash. Once the test is complete, (this may take up to 15 seconds) observe the tester panel:
   Fig 4: Pumping Handle Of Fuel Cap Tester

   
   • Green "PASS" LED (item #3 in illustration) flashing: fuel cap is serviceable. DO NOT REPLACE  the fuel cap.

     Diagnose EVAP system further as required (depending on which DTC has been stored).

   • "OBDII FAIL" LED (item #2 in illustration) or "I/M FAIL" LED (item #5 in illustration) flashing: ensure the gasket is clean and undamaged. If needed, clean the gasket and re-test. REPLACE  the fuel cap if the test fails a second time.
   NOTE: All technical readings MUST be recorded on the Repair Order shop copy.