SAAB EVAP Update & ORVR Workbook 1

Transcription

1 SAAB EVAP Update & ORVR Workbook 1 Instructions for this Interactive Training course: 1. Read the objectives of this self study course on the next page. This will give you a good idea of what you can expect to learn from these materials. 2. This EVAP Update & ORVR System self-study course will cover these topics: A review of the Enhanced EVAP system found on many Saab models since An overview of the On-board Refueling and Vapor Recovery system found on most Saab models since An introduction to the Kent-Moore J Evaporative Emissions Systems Tester. 3. View the multimedia presentation at saab-edu.com first. (This will take approximately 20 to 30 minutes). 4. After viewing the multimedia presentation, read the technical descriptions on pages 3 to 17 of this workbook before performing the on-car activities. 5. Perform the workbook exercises on pages 18 through 33. You will need to use Tech 2 and the J Tester on a 2000 (or newer) 9-5 while completing the workbook activities. (An earlier vehicle may be used, but some Tech 2 screens will have a different appearance.) 7. When you have performed all of the worksheet activities, log on to saabedu.com, click on EVAP Update & ORVR Course, then click on ORVT Test this will bring you to the secure Saab testing site. You will need to enter your IRIS user ID to enter the secure testing site. Locate the ORVT Test on the Technical Training page. You can print out the test, log off of the testing site, answer the questions, then log back on to enter your answers on-line.

2 2 EVAP Update & ORVR Workbook SAAB EVAP System Update Workbook - Objectives After viewing the video and completing this self-study workbook, you will be able to: explain the operation of the components of the EVAP system and the ORVR system, including: fuel tank pressure sensor EVAP purge valve float valve rollover valve fuel tank non-return valve canister canister close valve filler pipe locate all the components of the EVAP system and the ORVR system. activate the EVAP diagnosis Tech 2 function and explain the test results. explain how the enhanced EVAP diagnostics on 1998 and later vehicles differs from the version found on 1996 and 1997 models. list the EVAP system version on any late model Saab. setup the J Evaporative Emissions System Tester. explain various methods used to connect the J Evaporative Emissions System Tester to the vehicle. locate an enhanced EVAP system leak using J Evaporative Emissions System Tester.

3 SAAB EVAP Update & ORVR Workbook 3 Introduction to EVAP System Variants There are many engine management system variations involving the EVAP system on 1996 and later SAAB models. The chart below lists all of the 900, 9-3 & 9-5 variants. Vehicle EVAP System Application Chart Engine Engine Management System Enhanced EVAP? ORVR? M96 - M Nat. Asp. Motronic 4.1 (OBD II) NO NO M96 - M Turbo Trionic T5 OBD II YES (1996 ½ >) NO M96 - M V6 Motronic 5.2 (OBD II) YES NO M Nat. Asp. Motronic 4.1 (OBD II) NO YES M Turbo Trionic T5 OBD II YES YES M Turbo Trionic T5 OBD II YES YES M99 Viggen 2.3 Turbo Trionic T7 YES YES M VIN <20000 M VIN 20001> 2.3 & 3.0 Turbo 2.3 & 3.0 Turbo Trionic T7 YES NO Trionic T7 YES YES M2000 to M02 All models 2.0, 2.3 & 3.0 Turbo Trionic T7 YES YES Note that models DO NOT use either enhanced EVAP or ORVR. ****** Important Note Regarding This Workbook! ****** This workbook is designed to give you an overview of all enhanced EVAP systems, the ORVR system, and the Kent-Moore J Evaporative Emissions System Tester.. Unless stated otherwise, all worksheets in this publication pertain to M models. Illustrations are generic in nature and do not apply to any individual model. Even though many of the operating principles and components are the same, there are slight variations from year to year and system to system. A good example of this is the ORVR system as used on the naturally aspirated variant with Motronic 4.1. Since this engine management system is not designed with enhanced EVAP, you will not find a Canister Close Valve or a Tank Pressure Sensor.

4 4 EVAP Update & ORVR Workbook SAAB Onboard Refueling Vapor Recovery (ORVR) System Figure 1. ORVR System Filler pipe Non-return valve, fuel tank Fuel Tank Float Valve Evaporative emission canister Canister Close Valve Pressure sensor, fuel tank EVAP purge valve Shut-off valve, rollover

5 SAAB EVAP Update & ORVR Workbook 5 Main Components - ORVR Figure 2. ORVR System Components & Locations 1. Fuel Tank 2. Pressure sensor, fuel tank (585) M98, moved to the top of the tank, left hand side. 3. Shut-off valve, rollover - mounted on the tank. Non-ORVR cars, mounted on the filler neck. 4. Float Valve - mounted on the tank 5. Evaporative emission canister usually behind or above the fuel tank 6. Non-return valve, fuel tank - at the lower end of the filler pipe 7. Canister Close Valve (588) - moved to a position inside the right rear wheel well 8. Filler pipe Mounting point for the tank pressure sensor, M96 & M97) 9. EVAP purge valve (321) - same position as previous models

6 6 EVAP Update & ORVR Workbook SAAB Brief Description - ORVR Vehicles concerned Most 1998 and later models for the USA and Canada, see the chart on page #3. Legal requirements ORVR, Onboard Refueling Vapor Recovery, is a legal requirement which came into force on September 1, 1997 in the United States. It governs hydrocarbon emissions in connection with refueling. The ORVR system was phased in gradually. All manufacturers had to equip 40% of their US models with ORVR for the 1998 model year. This increased to 100% for model year All hydrocarbons formed when refueling must be recovered by the car and not released into the atmosphere. A maximum of 0.2 grams of hydrocarbons per gallon of fuel may be permitted to escape when filling up with 4-10 gallons of fuel per minute. It must be possible to fill up 95% of the total tank capacity at a rate of 4-10 gallons of fuel per minute without the fuel pump nozzle shutting off prematurely and necessitating subsequent topping up. Leakage larger than that caused by a hole corresponding to a diameter of 1 mm (0.040 ) must be detected by the enhanced EVAP system, if equipped. (Not Motronic 4.1) System description Fuel is poured into the tank through the filler pipe, passing a non-return valve before actually entering the tank. The fuel presses out the gaseous hydrocarbons and air in the tank, causing them to pass through the float valve and into the evaporative emission canister. The hydrocarbons are absorbed in the evaporative emission canister and the air escapes through the canister close valve. The float valve closes at a certain level (about 95%). The pressure in the tank then increases and the non-return valve also closes. The fuel now rises in the filler pipe and the fuel pump nozzle shuts off when the fuel reaches it. The volume of vapor remaining in the tank passes slowly through the rollover valve and into the evaporative emission canister. As the vapor disappears, fuel runs down from the filler pipe which empties. When the engine is subsequently started, the evaporative emission canister is gradually purged as air is sucked into it through the canister close valve. The hydrocarbon/air mixture passes through the EVAP canister purge valve and into the engine where it is burnt. Note that beginning with certain 2002 models, the enhanced EVAP system software will have to detect a leak corresponding to a hole of 0.5mm (0.020 ) diameter. (The 2002 and later Saab 9-5 and the 2003 and later Saab 9-3 will be required to meet this specification.)

7 SAAB EVAP Update & ORVR Workbook 7 Component Description - Filler Pipe, Non-return Valve Figure 3. Filler Pipe, Fuel Tank Non-return Valve Filler pipe Fuel is poured into the tank through the filler pipe (25 mm diameter). It then passes through a non-return valve before actually entering the tank. Non-return valve, fuel tank The non-return valve ensures that the fuel vapor (hydrocarbons) in the tank is not carried back up in the filler pipe. High up in the filler pipe is an insert to ensure that the fuel pump nozzle makes a good fit in the pipe when refueling. Additionally, this insert is designed to draw in ambient air during refueling. This ensures that all fuel vapors are drawn into the fuel tank. Important Draining the fuel tank must not be done by siphoning off the fuel via the filler pipe. This will damage the filler pipe.

8 8 EVAP Update & ORVR Workbook SAAB Component Description - Fuel Tank, Float Valve Figure 4. Fuel Tank, Float Valve Fuel tank All tank components are plastic welded in position, except the pressure sensor and fuel pump. Since all of the components are plastic welded in position, individual components such as the float valve are not replaceable individually. If any component except the pressure sensor or the fuel pump is faulty, the complete tank assembly must be replaced. Float valve The float valve is connected to the evaporative emission canister by a hose. This prevents fuel in liquid form from reaching the evaporative emission canister. On refueling, the vapor in the tank passes through the float valve and into the evaporative emission canister until the tank is full. The valve then closes. A spring-loaded float closes the valve when the tank is approximately 95% full or in the event of a rollover.

9 SAAB EVAP Update & ORVR Workbook 9 Component Description - Canister, Canister Close Valve Figure 5. EVAP Canister, Canister Close Valve Evaporative emission canister The evaporative emission canister, which is mounted behind the tank, consists of a container filled with special charcoal in pellet form. Charcoal in pellet form is used so that the evaporative emission canister will exert as little backpressure as possible. The hydrocarbons which evaporate in the tank pass through a hose to the evaporative emission canister. The activated charcoal in the evaporative emission canister gradually becomes saturated as it absorbs the hydrocarbons. The evaporative emission canister is connected by hoses to the fuel tank and the intake manifold. There is also a hose connection to the surrounding air. When the engine is started, ambient air is sucked through the evaporative emission canister via the purge valve and into the intake manifold. The hydrocarbons mix with the air and are burnt in the engine. The evaporative emission canister absorbs about grams of hydrocarbons per full refueling of the tank. The time it takes to purge the evaporative emission canister of hydrocarbons depends on how the car is driven. It will be fully purged before the next refueling takes place. The evaporative emission canister can absorb 150 grams of hydrocarbons at most. Canister Close Valve (Shut-off valve) The canister close valve (sometimes called the shut-off valve) is connected to the evaporative emission canister's air connection and is supplied with current from the main relay. The valve is open when NOT energized. The shut-off valve is used for OBD II diagnostics. When the engine is running, the valve closes only when a tank integrity check is performed.

10 10 EVAP Update & ORVR Workbook SAAB Component Description-Pressure Sensor, EVAP purge valve Figure 6. Pressure Sensor, EVAP Purge Valve Pressure sensor, fuel tank A differential pressure sensor is mounted on the tank. It compares the pressure in the tank with barometric pressure. The pressure sensor is supplied with 5 V and ground from the control module. The pressure sensor output voltage will vary depending on the pressure difference between the tank and the atmosphere. EVAP canister purge valve The EVAP canister purge valve consists of a solenoid valve in the hose between the evaporative emission canister and the intake manifold. It is used to control the quantity of air/hydrocarbons from the evaporative emission canister that is passed into the engine and burnt. When there is no pressure difference, the output voltage from the pressure sensor will be about 2.5 V. The pressure sensor is used for OBD II diagnostics.

11 SAAB EVAP Update & ORVR Workbook 11 Component Description - Rollover Shut-off Valve Figure 7. Rollover Shut-off Valve Shut-off valve, rollover The rollover shut-off valve closes only in connection with a rollover and prevents fuel leakage should this happen. A hose connects the valve to the evaporative emission canister. Air which expands in the tank is purged through the valve and the evaporative emission canister.

12 12 EVAP Update & ORVR Workbook SAAB ORVR Operation - Refueling, tank less than 95% full 4. Air escapes via Canister Close Valve 2. Air and Fuel Vapors passing through Float Valve 1. Fuel entering tank (Liquid) 3. Fuel Vapors stored in Charcoal granules Liquid Fuel Fuel Vapors Air Figure 8. Refueling, less than 95% Full Refueling, less than 95% full When refueling, the fuel enters the filler pipe in liquid form. As the liquid fuel passes through the specially designed insert at the top of the filler pipe, a small amount of ambient air is drawn into the filler pipe. This ensures that all vapors will pass into the fuel tank. As the liquid fuel enters the tank, the fuel passes through a non-return valve. Fuel vapors and air will exit the tank through the float valve, which has a large opening. Air and fuel vapors must then travel to the canister where the fuel vapors will become absorbed in the activated charcoal. Air will then leave the canister and return to the atmosphere via the canister close valve. (Since the canister close valve is OPEN when not energized.)

13 SAAB EVAP Update & ORVR Workbook 13 ORVR Operation - Refueling, tank over 95% full 5. Air escapes via Canister Close Valve 3. Air and Fuel Vapors passing through Rollover Valve 4. Fuel Vapors stored in Charcoal granules 1. Fuel entering tank (Liquid) 2. Float Valve Closes Liquid Fuel Fuel Vapors Air Figure 9. Refueling, Over 95% Full Refueling, over 95% full As the level of the fuel in the tank approaches 95% full, the float valve closes. At this point, the air and fuel vapors in the tank exit through the rollover shut-off valve. This valve has a restriction in the fitting which is connected to the canister. This restriction will only allow the air and fuel vapors to pass through very slowly, therefore the liquid fuel backs-up in the filler neck and causes the dispensing nozzle at the gas pump to shut off. The air and fuel vapors in the tank will pass through the rollover shut off valve, allowing the column of liquid fuel to slowly drop into the gas tank. Note that there is a hose connected from the float valve / rollover shutoff valve to the upper end of the filler neck. This hose allows the liquid column of fuel to drop into the tank if the gas cap is installed before the filler pipe has fully drained into the tank.

14 14 EVAP Update & ORVR Workbook SAAB ORVR Operation - Normal Purge Fuel Vapors Air Figure 10. Normal Purge Cycle Normal Purge Cycle Fuel vapors which have been stored in the activated charcoal in the canister will be purged by being drawn into the engine and used for combustion. The purge valve is a solenoid which receives power from the main relay and is controlled by a PWM signal controlled by the ECM. The valve is supplied with a PWM pulsed ground at a frequency of 8 Hz and starts to operate when the following conditions have been met: Engine is operating in closed loop Engine Coolant temperature is above 40 C (104 F) on 1998 and later 900 Turbos.and T5 9-3s. [60 C (140 F) on 1996 & 1997 models] (50 C (124 F) on 9-5 models) Intake Manifold Pressure is below 90 kpa (low engine load) The ECM starts purging with very short ground pulses, the duration of which slowly increases. This allows the ECM time to compensate for the additional fuel being drawn in from the canister. On Trionic systems, the purge valve operates for 4 ½ minutes, then stops for ½ minute, then operates for another 4 ½ minutes, and so on. During normal canister purging, note that ambient air is drawn into the canister via the Canister Close Valve.

15 SAAB EVAP Update & ORVR Workbook 15 ORVR Operation - Tank Integrity Diagnosis (First Phase) 2. ECM continues to cycle the EVAP purge valve 1. Canister Close Valve is energized by ECM (valve closes) 3. The tank pressure sensor monitors the pressure drop (vacuum) which is developed in the tank. Figure 11. Tank Integrity Diagnosis Tank Integrity Diagnosis - First Phase All vehicles with enhanced EVAP (which includes Turbo models) must perform an integrity test of the EVAP system as part of the On-Board Diagnostics (OBD II). U.S. government regulations state that the ECM must be able to determine if there is a leak equivalent to a hole with a 1mm diameter. The integrity test is designed to run once per drive cycle. In order for the diagnostic routine to run, a certain set of conditions called enable criteria must be met. (Note that this is a simplified list of enable criteria. A detailed list of enable criteria for Turbo models is included on page 17.) Diagnosis not yet performed this trip Front oxygen sensor transition diagnosis is O.K. Vehicle speed has been 0 km/hr for 7 seconds Idle speed Normal purge has been active During the first phase of the diagnostic routine, the ECM stores a tank pressure reference value. Then the Canister Close Valve is energized, closing off the passage to ambient air. Next, the ECM cycles the purge valve with a fixed duty cycle of 13% The tank pressure must drop by at least -0.6 kpa within 23 seconds, or the ECM sets DTC P0455 which indicates a large leak. 9-3 & 9-5 models will display the message TIGHTEN FUEL FILLER CAP on SID.

16 16 EVAP Update & ORVR Workbook SAAB ORVR Operation - Tank Integrity Diagnosis (Second Phase) 2. ECM shuts off the EVAP purge valve (valve closes) 1. Canister Close Valve remains energized by ECM (valve closed) 3. The ECM checks that the pressure drop (vacuum) is maintained for a period of time. = Indicates the pressure drop (vacuum) being held in the system Figure 12. Tank Integrity Diagnosis Tank Integrity Diagnosis - Second Phase If an adequate pressure drop (a vacuum) is obtained during the first part of the diagnostic routine, the ECM will attempt to hold that pressure drop (vacuum) for a period of time in order to check for a small leak. (Remember, these specifications are for turbo models and may be slightly different for other variants and other years. For example, on Turbo models, tank pressure must not rise by more than 0.3kPa in 15 seconds.) In order to do this, the ECM shuts off the purge valve, but keeps the Canister Close Valve energized (closed). At this point, the tank pressure must not rise more than 0.3 kpa in 9 seconds, or the ECM sets DTC P0442 which indicates a small leak.

17 SAAB EVAP Update & ORVR Workbook 17 Setting Diagnostic Trouble Codes and Illuminating the Malfunction Indicator Lamp (Check Engine Light) 1996 & 1997 models On 1996 and 1997 models with enhanced EVAP, if one of the previous tests failed, a DTC will now be stored in memory. If the tank integrity test fails during the next drive cycle in which the diagnostic routine runs, then the MIL is illuminated Turbo, 9-3 & > models with enhanced EVAP have a slightly different logic for setting the DTC in memory: When starting a cold engine (coolant temperature below 40 C), the ECM will run the diagnostic routine as the engine is warming up. This is considered a cold test. If the system passes the cold test, then the diagnostic routine is complete for this trip. If the system fails the cold test, the DTC is NOT set yet. The ECM will perform a warm test. If the system now also fails the warm test, then a DTC will be set in memory, but the MIL will not be illuminated. If the system fails both the cold test and the warm test during the next drive cycle, then the MIL will be illuminated. Tech 2 Activate EVAP Integrity Diagnose function. Because it is very difficult for the technician to duplicate these temperature conditions when validating a repair, Tech 2 has a function which can be used on 1998 and later vehicles with enhanced EVAP.. On the Activate menu, an item has been added entitled EVAP Diagnose. The EVAP Diagnose function will force the software to run the diagnostic routine once. The Tech 2 display will show the technician whether or not the system is leaking, a DTC WILL NOT be set if the system is leaking. If the fuel level is very high (above 85% full) or if there are a lot of fuel vapors in the tank, the diagnosis can not run. For this reason, perform this test with the fuel tank no more than ¾ full, and follow the instructions on the Tech 2 display to increase the engine load (thereby increasing air flow). There is a worksheet later in this book which will lead you through this Activate command step-by-step. Enable Criteria for M Turbo (9-3 & 9-5 Are Similar) Cold test: Diagnosis not yet done this drive cycle Diagnosis has been attempted less than 8 times this drive cycle. Coolant Temp below 40 C at start Idle 0 km/hr for more than 5 seconds Warm test: Cold test indicates leak (or - coolant temp above 40 C at start) Diagnosis not yet performed this trip Diagnosis has been attempted less than 8 times this trip O2S1 transition diagnosis is O.K. Idle 0 km/hr for more than 5 seconds Purge Valve duty cycle above 40% at least once during drive cycle.

18 18 EVAP Update & ORVR Workbook SAAB Introduction to Worksheets Now that you have a theoretical background on the system, it is time to perform some practical exercises on the car. The remainder of this workbook includes activities for you to perform which will help you to learn about the ORVR system and EVAP system diagnostics. These worksheets include the following activities: Locate & Identify components Review of System Operation Review of On-Board Diagnostic logic Tech 2 EVAP Diagnose function Use of the Kent-Moore J Evaporative Emissions System Tester Setup Self-test Calibration Activating the Canister Close Valve using Tech 2. Verification Mode (using Nitrogen to verify that a leak is present) Diagnostic Mode (using Smoke to locate the source of a leak) For best results use a M2000 to M for the on-car activities. M2000 to M models have very similar functions electronically but the components are naturally in different locations. Other vehicles listed on page 3 as having both ORVR and Enhanced EVAP may be used but the Tech 2 screens will be somewhat different from those shown on the following pages.

19 SAAB EVAP Update & ORVR Workbook 19 Exercise #1: Component Location & Identification 1. Remove Gas Cap - Notice the vacuum relief valve. 900 models have used this type of gas cap since model year 2. Look inside the filler neck, what is the function of the insert? 3. Raise the vehicle on a lift. Locate the Canister Close Valve. (Also called CCV, EVAP Shut Off Valve, Solenoid Valve EVAP Shut Off, and Shut Off Valve Evaporative Emissions Canister ). On the illustration below, draw an arrow to show the air inlet passage into the Canister Close Valve. 4. How would you get to the CCV (Canister Close Valve) if you needed to replace it? (Don t actually do it this time, you might unseat a few o-rings and have a real EVAP leak on your hands.) 5. Where is the charcoal canister located on a 9-5 with ORVR?

20 20 EVAP Update & ORVR Workbook SAAB 6. If you re working on a 9-5, we can t easily see the canister. We don t want you to drop the fuel tank now. HOWEVER, from the illustrations in this workbook, you know that the hose which is connected to the TANK port on the canister travels to the top of the tank. This hose is connected to the valve, and the valve. 7. There is another small hose which is connected from the top of the tank to the filler neck. This hose helps allow the liquid fuel to drain into the tank after the gas cap is installed, and this hose also allows the diagnostic software to detect if the is missing. 8. The hose which is connected to the PURGE port on the canister travels all the way to the front of the vehicle, and is connected to the EVAP valve. (By the way - we should remember that this valve is OPEN / CLOSED when it is not energized by the ECM.) 9. Which model has ORVR, but DOES NOT have the enhanced EVAP system? 10. Which 9-5 model has Enhanced EVAP, but does NOT have ORVR? Continue on the next page ->

21 SAAB EVAP Update & ORVR Workbook Fill in the missing information in the chart regarding location of EVAP system components on various models. You should use WIS for reference. Year & Model Canister Location CCV Location EVAP Service Port Location 96 ½ & turbo Right Front Inner Fender Right Front Inner Fender Not factory installed turbo Installed only on late 1998 production vehicles firewall right hand side Firewall right hand side (to VIN 20000) Firewall right hand side (VIN and later) 2000 to When you look at this chart with all of the information filled in, do you notice a pattern related to the location of Charcoal Canister and CCV? (Hint: compare the location of the components on vehicles with enhanced EVAP AND ORVR to vehicles with enhanced EVAP but WITHOUT ORVR.) On vehicles with enhanced EVAP AND ORVR, the canister and the CCV are usually located. On vehicles with enhanced EVAP but WITHOUT ORVR, the canister and the CCV are usually located.

22 22 EVAP Update & ORVR Workbook SAAB Exercise #2: ORVR System Operation Fill in the blanks: 1. When refueling, liquid fuel enters the filler neck. The insert at the top of the filler neck increases the velocity of the fuel and draws in ambient air, this ensures that all are drawn into the tank while refueling. 2. As the liquid fuel enters the tank, fuel vapors leave the tank through the valve and on to the canister. The vapors are stored in the activated charcoal and air exits the canister through the large hose. The air passes back into the atmosphere after passing through what component? 3. As the fuel tank approaches 95% full, the valve closes. This causes the liquid fuel to back up in the filler neck and shut off the dispenser nozzle. Fuel vapors slowly pass through the valve and on to the canister, allowing the liquid column of fuel to slowly drain into the tank. Normal Purge 1. On a Turbo (or any 9-3 or 9-5), when the engine is running and the coolant temperature is above C, normal purge can occur. 2. During normal purge, ambient air enters the canister after passing through the valve. The air is then drawn through the activated charcoal, and the air/vapor mixture pass through the EVAP purge valve and are drawn in the engine at the. 3. On Saab equipped with Trionic, normal purge will usually occur for minutes, then the ECM stops purge for seconds.

23 SAAB EVAP Update & ORVR Workbook Exercise #3: On-board EVAP System Leak Diagnosis & 1997 Trionic (900) Describe the enable criteria which must be fulfilled in order for the ECM to run the EVAP diagnostic routine (simplified list): Diagnosis not yet performed this trip transition diagnosis is O.K. has been 0 km/hr for 7 seconds Idle speed Normal purge has been active 2. The diagnostic routine will now occur (fill in the blanks with the values for a Turbo): the ECM stores a tank pressure reference value the Canister Close Valve is energized the ECM cycles the purge valve with a duty cycle of % tank pressure must drop by at least -0.6 kpa within seconds, or the ECM sets DTC P which indicates a large leak. if the tank pressure sensor identifies an adequate pressure drop in the first phase of the test, the ECM shuts off the purge valve, but keeps the Canister Close Valve energized (closed). At this point, the tank pressure must not rise more than 0.3 kpa in seconds, or the ECM sets Diagnostic Trouble Code P which indicates a small leak. 3. When the ECM detects a leak the first time, is a DTC stored in memory? YES / NO When the ECM detects a leak the first time, is the MIL illuminated? YES / NO 4. On a 1996 or with enhanced EVAP, the MIL will be illuminated only if

24 24 EVAP Update & ORVR Workbook SAAB Exercise #4: On-board EVAP System Leak Diagnosis 1998> Trionic Fill in the blanks according to the EVAP system diagnostic routine for a Turbo (or any model year 9-3 & 9-5): 1. When starting a cold engine (Engine Coolant Temperature less than C), the ECM will initially run an EVAP system cold test. 2. If the system PASSES / FAILS (circle one answer) the cold test, then the diagnostic routine is complete for this trip. 3. If the system FAILS the cold test, then the ECM will perform. 4. If the system FAILS the cold test, a Diagnostic Trouble Code WILL / WILL NOT (circle one answer) be set. 5. If the system also fails the warm test, then a will be set in memory. 6. If the system fails both the cold test and the warm test during the next drive cycle in which the diagnostic routine occurs, then.

25 SAAB EVAP Update & ORVR Workbook Exercise #5: Tech 2 Usage 9-3 & ** The following screens were captured on a using a Tech 2 loaded with version 42:000. Later software will probably give slightly different screens but the basic functions should remain the same.. 1. Before you begin this worksheet, make sure that all of the components of the EVAP system are connected, and the gas cap is on tight. Fuel tank level should be LESS THAN ¾ full. 2. Connect Tech 2, turn the ignition on, but DO NOT start the engine. Establish communication with Trionic: Diagnostics / model year / 9-5 / Engine / Trionic 7 3. Select F1: Read Values / Activate. 4. Press the Activate soft key. Use the right arrow key to page down to the bottom of the Activate list. Your display should look something like this: Activate Ignition Coil Cyl 2 Ignition Coil Cyl 3 Ignition Coil Cyl 4 Throttle Motor PWM Test (30s) Fuel Pump Flow Test (30s). Injector 1 Flow Test (30s). Injector 2 Flow Test (30s). Injector 3 Flow Test (30s). Injector 4 Flow Test (30s). Canister Purge Valve EVAP Integrity Diagnose EVAP Integrity Diagnose 23/25 With EVAP Integrity Diagnose highlighted, press ENTER. Turn to the next page

26 26 EVAP Update & ORVR Workbook SAAB 5. With engine off, next screen shows: Note: T7 cars don t show this screen. Trionic ODB II Start Engine and press OK OK 6. Start the engine, then press the OK soft key. Tech 2 will display an information screen with instructions regarding the EVAP Diagnosis: Information To make EVAP Diagnose run: - Engine Running - Gear in P or N - Do not touch Brake Pedal - Do not touch Accelerator Pedal - Closed Loop Note: If the diagnose has been interrupted (Canister Close Valve only closed for a short while), vehicle speed above 1 km/h must be performed. Rotate LH front wheel. OK

27 SAAB EVAP Update & ORVR Workbook When you press the OK soft key now, Tech 2 will display a graph of the tank pressure and CCV status: EVAP Integrity Diagnose Status: NOT READY Result: Tank Pressure kpa CCV XXX Max 0.0 Min 0.0 Help CURR With NO LEAKS in the system, you will see a line graph that looks something like this (It may take one to two minutes before the diagnostic routine runs.): EVAP Integrity Diagnose Status: READY Result: OK Tank Pressure kpa CCV XXX Max 0.0 Min Help CURR 0.0 Note that under certain conditions, the Activate EVAP Diagnose function may not run the diagnostic routine. If the diagnostic routine has not run after several minutes, shut the engine off, shut off Tech 2, wait 1 to 2 minutes, then re-establish communications with Tech 2, restart the engine and try to run the diagnostic routine again.

28 28 EVAP Update & ORVR Workbook SAAB 9. Answer these questions related to the line graph on the previous page: The thick line indicates? The thin line indicates? Max Tank Pressure Recorded: kpa Min Tank Pressure Recorded: kpa 10. Shut off the engine. Leave Tech 2 connected. 11. Remove the gas cap, and repeat the EVAP Diagnose again. After the test runs, you should see a display like this. Note that the Result indicates a system that is Leaking EVAP Integrity Diagnose Status: READY Result: P0455 Tank Pressure kpa CCV XXX Max 0.0 Min 0.0 Help CURR Check for DTCs. There are no DTCs because on an Turbo and all later vehicles, the diagnostic routine must fail during a test and also during a test in order to set a DTC.

29 SAAB EVAP Update & ORVR Workbook Exercise #6: Kent-Moore J Evaporative Emissions System Tester Usage 29 Introduction In January, 2002, Saab Cars USA introduced the Kent-Moore Evaporative Emissions System Tester. This test station is designed to test for leaks in the evaporative emissions systems (fuel tank, charcoal canister, purge lines, etc.) The tester actually has two modes: A Validation Mode in which the machine will inject nitrogen into the evaporative emissions system. During this mode, we observe a flow meter in order to determine if the system is leaking this mode helps to validate the on-board diagnostic function. A Diagnostic Mode in which the machine will inject smoke into the evaporative emissions system. During this mode, we perform a visual check of the components in the evaporative emissions system in order to locate a leak. The smoke generated by the machine will be seen exiting the system at the source of the leak.

30 30 EVAP Update & ORVR Workbook SAAB Initial Assembly Your machine may already have been set up by another technician at your dealership. (Or maybe you are the lucky one!) Either way, answer these questions pertaining to the setup of the J Tester. Refer to the Operation Manual for the J Evaporative Emissions System Tester. 1. The smoke from this machine is generated by Smoke Producing Fluid. What is the Kent-Moore part number for this fluid? How much fluid does the machine hold? oz. 2. The color hose is connected to the pressure regulator on the nitrogen tank on the back of the cart. (When you open the valve on a NEW tank of nitrogen, the pressure gauge on the regulator indicates over 500 PSI. You know it is almost time to replace the nitrogen tank when the pressure gauge drops below approx. 100 PSI.)

31 SAAB EVAP Update & ORVR Workbook 31 Front Control Panel Here is a view of the Front Control Panel of the Tester. 1. Let s begin by connecting the Power Cable to the vehicle s battery. (Red cable to the battery positive post, Black cable to the engine block to avoid sparks.) 2. Turn the Nitrogen / Smoke Valve to the Nitrogen position. (Make sure that the Nitrogen tank valve is turned ON.) 3. Hold the end of the blue Nitrogen / Smoke hose in the air. Press & Release the remote switch (this is a momentary contact switch press it once to turn the machine on, press again to turn the machine off.) Can you feel the very small pressure at the green fitting at the end of the blue hose? (remember - this is approx ½ PSI maximum) Press & Release the remote switch again to shut off the pump. 4. Turn the Nitrogen / Smoke Valve to the Smoke position. 5. Hold the end of the blue Nitrogen / Smoke hose in the air. Press & Release the remote switch (this is a momentary contact switch press it once to turn the machine on, press again to turn the machine off.) Can you see the smoke coming out of the green fitting on the end of the blue hose? Press & Release the remote switch again to shut off the pump.

32 32 EVAP Update & ORVR Workbook SAAB Self-test Refer to page #5 of the Operation Manual for the J Evaporative Emissions System Tester. (Step #11 A through #11 L.) This test is done to make sure that the pressure regulator settings are O.K. 1. As you perform the Self Test, you will: Connect the blue Nitrogen / Smoke hose to the Self Test Port on the front of the control panel. Turn the Nitrogen / Smoke Valve to the Nitrogen position. Press & Release the remote switch (this is a momentary contact switch press it once to turn the machine on, press again to turn the machine off.) Monitor the pressure gauge on the front panel Pressure should rise & stabilize at 13 H2O 2. If the pressure gauge does not indicate 13 H2O, then you must adjust the pressure regulator. (Note that this adjustment is seldom necessary.) 3. Let s take a moment to explain what 13 H2O indicates: (Note that 13 H2O is expressed as 13 inches of water.) Of course, you are aware that pressure can be measured in PSI, Bar, or kilopascals. Well inches of water is another way of measuring a very small pressure (or a very small vacuum). Here s why inches of water is a more accurate way of measuring a very small pressure: Atmospheric pressure at sea level is approximately 14.7 PSI -or kpa -or 400 H2O Since 14.7PSI = 101kPa = 400 H2O, then: 13 H2O = approximately 0.5PSI Note that on many Saab vehicles, when we monitor the fuel tank pressure sensor with Tech 2, the maximum range is +1.25kPa to 2.5kPa. 1.25kPa translates to approximately 5 H2O. So under normal conditions, the pressure differential in the fuel / evaporative system is much less than 13 H2O (much less than 0.5PSI).

33 SAAB EVAP Update & ORVR Workbook 33 Calibrating the Flow Gauge The U.S. government has implemented two different specifications for On-Board Diagnostic EVAP leak detection. Initially, 1996 OBDII specifications required that the on-board diagnostics be able to determine there was a leak of 1.0mm diameter or larger. Beginning with model year 2002, a tighter specification is being phased in on these vehicles, the on-board diagnostics must be able to determine that there is a leak of 0.5 diameter or larger. Note that some 2002 model year vehicles have been given a waiver of this new tighter specification. Here are the specifications for Saab models: 1996½ up to Turbos (Trionic T5) : software must be able to determine a leak of 1.0mm diameter (0.040 ) 2002 and later and later 9-3: software must be able to determine a leak of 0.5mm diameter (0.020 ) We must begin our Verification Procedure by Calibrating the Flow gauge according to the proper test specification. 1. Turn the Nitrogen / Smoke Valve to the Nitrogen position. 2. Connect the Blue hose to the correct test orifice on the bottom-front of the tester as shown in the illustration.

34 34 EVAP Update & ORVR Workbook SAAB 3. Press & Release the remote switch to activate the pump in the tester. 4. Position the red flag on the flowmeter to align with the floating indicator as shown in the illustration. When the flag is set, press and release the remote switch to deactivate the pump in the tester.

35 SAAB EVAP Update & ORVR Workbook 35 Connecting the J41413 Diagnostic Station to the Vehicle 1. Do all models have a test port factory installed? 2. If you are testing the EVAP system on an early Turbo, Saab recommends that you permanently install a test port. 3. A test port was included with your J41413 Station (the test port is Kent-Moore # J43156). This test port has three uses: It can be temporarily installed on any ORVR car, if you do not have a test port in stock. (Take the rubber cap off of the end of the test port, and install a short length of hose. Make sure that you remove the test port when you are done so you always have one available with the test station.) On a 1996 or with enhanced EVAP, you can disconnect the hose which connects the EVAP purge valve to the canister (easy to get to - under the hood), and connect the test port to this loose hose end. (In this case, make sure that you leave the rubber cap in place.) If you are diagnosing an EVAP problem on ANY vehicle which DOES NOT have enhanced EVAP, you can disconnect the hose which connects the canister to the fuel tank, and connect the test port to this loose hose end. (In this case, make sure that you leave the rubber cap in place.) NON-enhanced EVAP cars do not have a Canister Close Valve. This means that on most of these vehicles, you cannot pressurize the canister. You can only pressurize the tank, filler neck, and the hose from the canister back to the tank. How could you pressurize a naturally aspirated EVAP system? 4. A gas cap adapter was included with your J41413 Station. This can be used to connect the J41413 Station to the vehicle. However, Saab recommends that you leave the vehicle s own gas cap in place during your diagnosis, if possible. If there was a leak at the gas cap sealing surface, it may be difficult to find after you have removed the gas cap and installed the gas cap adapter.

36 36 EVAP Update & ORVR Workbook SAAB Verification of a Leak (Note that these Tech 2 displays were captured using software version on a Other models with enhanced EVAP and ORVR will be similar.) 1. For the remaining worksheets, attach the J Tester to the test port on the vehicle, or use the test port adapter (J43156) included with your Tester. As explained on the previous page, you should connect the blue hose to the factory installed test port whenever possible. 2. Before pressurizing the system, the canister close valve must be energized (closed). {Remember that 1996 and models with enhanced EVAP require a jumper wire to energize this valve. Directions for building this jumper harness are listed in PSI number 01/ (section 2, page 61).} On current models, use Tech 2 to ACTIVATE the Canister Close Valve: Diagnostics / year / 9-5 / Engine / Trionic 7 3. Select F1: Read Values / Activate. 4. Press the Activate soft key. Use the right arrow key to page down to the bottom of the Activate list. Your display should look something like this: Activate Ignition Coil Cyl 3 Ignition Coil Cyl 4 Throttle Motor PWM Test (30s) Fuel Pump Flow Test (30s). Injector 1 Flow Test (30s). Injector 2 Flow Test (30s). Injector 3 Flow Test (30s). Injector 4 Flow Test (30s). Canister Purge Valve Canister Close Valve EVAP Integrity Diagnose Canister Close Valve 22/25 With Canister Close Valve highlighted, press ENTER. Turn to the next page

37 SAAB EVAP Update & ORVR Workbook With the engine off, the next screen shows: Trionic 4 cyl OBD II, LEV 0 10 Canist. Close Valve ON Manual View OFF Auto Data 6. Select Manual and press the ON soft key now. The Canister Close Valve will remain closed until you press the OFF button. 7. If you are testing a vehicle with the Trionic T5 fuel system, the Activate screen will be considerably different. The bottom of the screen will look like this: Activate Repeat 1 Increase the Repeat value to 10 pressing the Repeat soft key, this will increase the CCV closed time to 100 seconds. (You can select Repeat 1000 but the current software releases the valve at 100 seconds.). 8. Turn the Canister Close Valve ON. Turn to the next page

38 38 EVAP Update & ORVR Workbook SAAB 9. Turn the Nitrogen / Smoke Valve to the Nitrogen position. 10. Press & release the remote switch to activate the nitrogen flow and fill the system. Watch the pressure gauge on the control panel. As the system is being pressurized, the pressure gauge on the control panel will begin to rise. It may take a couple of minutes to fill the system with nitrogen, depending on the fuel level in the tank. You should press & release the remote switch a couple of times as the system is filling with nitrogen. This will help avoid static electricity holding the flowmeter indicator ball in one position. Unless there is a large leak, the pressure gauge should reach 13 H2O within 2 minutes or so. 11. As the system approaches 13 H2O pressure, watch the flowmeter s indicator in relation to the red flag: If the indicator floats: ABOVE the red flag, the result is UNACCEPTABLE (FAILS the test). BELOW the red flag, the result is ACCEPTABLE (PASES the test). (NOTE: If you are working on a T5 car, current software will open the CCV and release pressure after 100 seconds. If you want to carry out an extended test activate the valve with the test harness described in PSI number 01/ , section 2, page 61). 12. Press & release the remote switch to deactivate the nitrogen flow.

39 SAAB EVAP Update & ORVR Workbook 39 Verification Mode - Simulated leak Now that you have seen how the equipment responds to a system which is not leaking, let s simulate a leak: 1. Loosen the fitting on the end of the blue hose slightly where it is attached to the test port or test port adapter. 2. Attempt to pressurize the system again. (Make sure that the canister close valve is activated with Tech 2 first!!!!) 3. Tighten the fitting on the end of the blue hose before proceeding with the next step. Turn to the next page

40 40 EVAP Update & ORVR Workbook SAAB Diagnostic (Smoke) Mode Let s begin with the gas cap TIGHT, so you can see how the machine reacts when the system has no leaks. 1. Make sure that the Canister Close Valve is still activated (either with Tech 2 or with a jumper wire). 2. Turn the Nitrogen / Smoke Valve to the Smoke position. 3. Press & release the remote switch to activate the smoke flow and fill the system. Note that this may take a couple of minutes depending on the fuel level in the tank. Begin by injecting smoke for about two minutes, then continue introducing smoke at 15 second intervals, as necessary. As the system is being pressurized, the pressure gauge on the control panel will begin to rise. It may take a couple of minutes to fill the system with smoke, depending on the fuel level in the tank. Unless there is a large leak, the pressure gauge will reach 5 H2O to 10 H2O within 2 minutes or so. When the system is being filled with smoke, you will not see 13 H2O displayed on the pressure gauge, even on a leak free system. 4. Now loosen the gas cap slightly, to simulate a leak. 5. Using the high-intensity white light (J41413 SPT, supplied), inspect the entire EVAP system path, and look for the source of the leak indicated by the exiting smoke. Introduce smoke at 15 second intervals, as necessary, until the leak source is identified. Note: For optimum visual smoke performance, deactivate the smoke flow and allow the pressure to drop slightly. Allowing the smoke to exit small holes at a low flow rate greatly enhances visibility. 6. Press & release the remote switch to deactivate the flow of smoke. Continue on the next page->

41 SAAB EVAP Update & ORVR Workbook Tighten the gas cap to repair the leak. 8. Once you have repaired the leak, repeat the verification process. (Also use Tech 2 to activate the diagnosis this is the best way to verify that the repair has been successful.) 9. Close the valve on the nitrogen tank, disconnect the J Tester. 10. Be sure to replace the green cover on the test port. If you used the J43156 test port included with your Test Station, be sure to remove it from the vehicle, and reattach the hose to the EVAP purge valve. This is the end of the Worksheet activities. The next few pages include answers to all of the worksheets. After you have reviewed any incorrect answers, and you are confident that you fully understand the system, log on to saab-edu, and follow the instructions to gain access to the ORVT Test. Instructions for the test can be found at saab-edu.

42 42 EVAP Update & ORVR Workbook SAAB Exercise #1: Answers to Worksheets models have used this type of gas cap since model year Look inside the filler neck, what is the function of the insert? to center the fuel filler nozzle, and to draw in a small amount of ambient air to ensure that all vapors are drawn into the tank 3. Air Inlet 4. How would you get to the CCV if you needed to replace it? You would remove the plastic cover over the CCV. 5. Where is the Charcoal canister located on a 9-5 with ORVR? On top of the fuel tank the tank must be lowered to see the canister or to replace the canister. 6.. But you know from the illustrations that this hose is connected to the Float valve, and the Rollover Shut-off valve this hose also allows the diagnostic software to detect if the gas cap is missing. 8.. and is connected to the EVAP purge valve. (By the way - we should remember that this valve is CLOSED when it is not energized by the ECM.)

43 SAAB EVAP Update & ORVR Workbook Which model has ORVR, but DOES NOT have the enhanced EVAP system? naturally aspirated (Motronic 4.1) 10. Which 9-5 model has Enhanced EVAP, but does NOT have ORVR? models up to VIN (early 99 production) 11. On vehicles with enhanced EVAP AND ORVR, the canister and the CCV are usually located below the rear of the vehicle On vehicles with enhanced EVAP but WITHOUT ORVR, the canister and the CCV are usually located inside the right front fender)

44 44 EVAP Update & ORVR Workbook SAAB Exercise #2: 1., this ensures that all fuel vapors are drawn into the tank while refueling. 2., fuel vapors leave the tank through the float valve and on to the canister. The air passes back into the atmosphere after passing through what component? Canister Close Valve 3. As the fuel tank approaches 95% full, the float valve closes. Fuel vapors slowly pass through the rollover shut-off valve and on to the canister,.. Normal Purge 1. coolant temperature is above 40 C ambient air enters the canister after passing through the Canister Close valve..and are drawn in the engine at the intake manifold (or throttle housing). 3. On Trionic cars, normal purge will usually occur for 4 ½ minutes, then the ECM stops purge for 30 seconds. Exercise #3: 1. - Front Oxygen Sensor (O2S1) transition diagnosis is O.K. - Vehicle Speed has been 0 km/hr for 7 seconds 2. - The ECM cycles the purge valve with a duty cycle of 13 % - tank pressure must drop by -0.6 kpa within 23 seconds, or the ECM sets DTC P 0455 which indicates a large leak. - At this point, the tank pressure must not rise more than 0.3 kpa 15 seconds, or the ECM sets DTC P 0442 which indicates a small leak. 3. When the ECM detects a leak the first time, is a DTC stored in memory? YES When the ECM detects a leak the first time, is the MIL illuminated? NO 4. On a 1996 or with enhanced EVAP, the MIL will be illuminated only if the test fails during the next drive cycle in which the diagnostic routine runs