September 2805

FUEL CAP TESTER

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.

File Under: Special Service Tools

Circulate To: General Manager Service Manager Parts Manager

Service Advisor(s) Technician(s) Body Shop Manager Fleet Repair
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SERVICE P R O C E D U R E
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.
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 #I 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 APQM BEGINS

LED (item #2 in illustration) will illuminate

when the tester is ready.
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.

TSB: Special Service Tools 008 September 2005

 Page 3 of 3

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:
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 "IIM 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.

* NOTICE
All technical readings MUST be recorded
on the Repair Order shop copy.

TSB: Special Service Tools 008 September 2005