Technical Service Group

FUEL SYSTEM
Bulletin Number
02-30-001
Subject Date
ENHANCED EVAPORATIVE EMISSION
CONTROL DIAGNOSIS AND REPAIR FOR DECEMBER, 2002
P0442, P0456, P0455 AND P1443 LEAK CODES Model
USING A LOW PRESSURE GAUGE ALL MODELS

DESCRIPTION:
This TSB is an addendum to TSB 00-30-003. Technicians already familiar with TSB
00-30-003 will benefit from the new diagnostic tree. Several revisions are embedded
into the diagnostic tree, and a summary of the revisions can be found on page 4. New
technicians can start with the diagnostic tree and refer to TSB 00-30-003 for additional
information.
INTRODUCTION:
By pressurizing a sealed evaporative emission system, the pressure leakdown rate can
easily be measured using a low pressure gauge. The system should be slowly
pressurized to a very low pressure (in this case 20” H2O). A properly operating
system (one that does not leak) will not lose any pressure; in fact, with high fuel
temperature and high ambient temperature, pressure may increase due to fuel
vaporization. A very small leak is read as a 2” H2O drop of pressure over one minute.
This tool is intended to verify and diagnose evaporative emission leaks with Diagnostic
Trouble Codes (DTCs) P0456, P0442, P0455, P0457, and P1443. In some instances
DTCs P0440 and P0441 can also be diagnosed.

Low Pressure Gauge Tool (L.P.G.T.) - SPX EVAP Tester P/N J-44680

Interchangeable Pressure Tips for using the low pressure gauge.

nylon hose barb Release
Valve
1. Pressurize evap system to 20” H2O for testing.
2. Never use shop air, or pressurize beyond 30” H2O.
3. Always use teflon tape or sealer on the hose barb
One-Way connection.
Valve
4. Use a hose clamp over the connection hose.
5. Use hose pinching pliers to clamp off sections
to isolate the leak.
6. Use a bungee cord (or equivalent) to support
Low Pressure the tool to prevent kinked hoses.
gauge

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 LOW PRESSURE GAUGE LEAK CHECK: DIAGNOSTIC TREE

EVAPORATIVE EMISSION To Purge

LEAK CODES VERIFIED:
2
(one or more)
Charcoal
3 To Tank
P0456, P0442, P0455, Canister
P0457, P1443

1/2” hose
Canister Close
Pre-Test Conditions: Valve
- Fuel tank below 1/4 or
(low fuel light on is best) DM-TL 1
- Fuel cap NOT adjusted by Low Pressure Gauge Tool
service writer/manager

A B C

Connect low pressure gauge

At the canister, pinch the
tool on the “fresh air” side of
purge hose (# 2 in the diagram) Tighten/Adjust the fuel cap
the charcoal canister
with hose pinching pliers
(# 1 on diagram)

Continues to Leak Continues to Leak

Pressurize to 20” H2O, adjust
GO TO "C" GO TO "D"
to 20” H2O after 30 seconds.

After adjustment, pressure OR OR

should not decrease 2" H2O
in one minute.
Leakage Stops Leakage Stops
DO NOT USE SHOP AIR

No Leak Detected Loose or improperly

Check for leaking hose(s)
Skip to "F" installed fuel caps by
between # 2 and (including)
the Canister Purge Valve. the customer are not
warrantable.
OR

Continues to Leak
GO TO "B" END END

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 Technical Service Group
FUEL SYSTEM
Bulletin Number
02-30-001

D E F G

1. Inspect the fuel cap No leak detected No leak detected

At the canister, pinch for obvious damage But vehicle has DTC But vehicle has DTC
the “to-tank” hose such as missing o-ring P0456, P0442, P1443,
P0455 ONLY
(# 3 in the diagram) and/or missing vaccum
(if there are other or P0457 or P0455
valve assembly.
additional DTC’s: stored in the ECM
2. Use soapy water GO TO "G")
and pressurize up to
20” H2O to detect
leaks in the following
locations:

Hoses
Leakage Stops Hose Clamps Verify that vacuum
Inspect CCV date
GO TO "E" 1-2-4 way valves from purge valve is
code located under the
Fill Vent Valve reaching to canister.
stamped part number
Rollover Valve If yes:
020826 = Aug. 26, 2002
Fuel Pump Plate GO TO "G"
Filler Neck
Fuel Tank
Liquid-Vapor Separator
Continues to Leak
Note: Don’t forget to
check the hoses at the
one way valve at the top
of the filler neck

Using soapy water and
pressure, check for leak
in the charcoal canister
assembly and replace damaged components
if necessary.
If no vacuum, search
Call Techline with
for restricted or
CCV datecode
blocked vapor hose
Repair or replace information
from intake manifold
800-325-6604
to canister; and repair.
as necessary.

END END END END

Summary of revisions from TSB 00-30-003:

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1. Fuel caps must NOT be tightened or adjusted prior to performing the leak check.
a. Fuel caps that are loose due to improper installation by the customer are
not warrantable. A loose fuel cap is not a result of a “defect in factory
material or workmanship”.
2. Fuel level must be below 1/4 to perform the low pressure leak check. The ideal
condition is with low fuel light on.
3. The pressure tester tool should be pinched with hose pinching pliers (such as Snap-
on P/N BLC2 or eqivalent) between the one way valve and the pressure release
valve.
4. Pipe thread sealer must be used on the hose barb connection of the pressure
gauge.
5. Canister close valve or DM-TL replacement should only be performed after proper
pressure checking.

SCHEMATIC DIAGRAMS: PAGE

Elantra/Tiburon 1996-1997 ...................................................................................5
Elantra 1998-2000 and 1998-2001 ......................................................................6
Elantra 2001-2003 Except SULEV/CVVT .............................................................7
Elantra 2003 SULEV/CVVT .................................................................................8
Tiburon 2003..........................................................................................................9
Accent 1997 DOHC and 1998 ............................................................................10
Accent 1999 ........................................................................................................11
Accent 2000-2003 ...............................................................................................12
Sonata 1998 All 3.0L and 2.0L California Specification Only ............................. 13
Sonata 1999-2003; XG300 2001, XG350 2002-2003.......................................... 14
Santa Fe 2001-2003 ........................................................................................... 15

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FUEL SYSTEM
Bulletin Number 02-30-001

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FUEL SYSTEM
Bulletin Number 02-30-001

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FUEL SYSTEM
Bulletin Number 02-30-001

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FUEL SYSTEM
Bulletin Number
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Technical Service Group
FUEL SYSTEM
Bulletin Number
02-30-001

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Technical Service Group
FUEL SYSTEM
Bulletin Number 02-30-001

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