Subject: | Service Manual Update for Powertrain and Engine Service Manuals Regarding Evaporative Emission Flowcharts and EVAP Pressure/Purge Diagnostic Cart Test Procedure |
Models: | 1998 - 2002 Saturn S-Series vehicles |
2000 - 2002 Saturn L-Series vehicles |
2002 Saturn VUE vehicles |
The purpose of this bulletin is to update P0440, P0442, and P0455 evaporative emission flowcharts and EVAP Pressure/Purge Diagnostic Cart Test Procedure to reflect the use of new special tool J41750-A, Evaporative Emissions System Tester, which replaces J41750. Update the flowcharts and EVAP Pressure/Purge Diagnostic Cart Test Procedure in the following service manuals:
• | All 1998/1999 Powertrain and 2000 - 2002 S-Series Engine Service Manuals. |
• | All 2000, 2001, and 2002 L-Series (L61) and (L81) Engine Service Manuals. |
• | All 2002 VUE Powertrain Electrical Diagnostic Service Manuals. |
Please obtain all service manuals indicated above at your location and make the necessary updates to each manual. Replace the service manual pages indicated in the tables with a copy of new DTC flowcharts or procedure page in this bulletin as indicated below.
"Refer to Technical Information Bulletin 01-T-02"
1998/1999 S-Series Powertrain Service Manuals | ||
---|---|---|
Flowchart/Procedure To Be Replaced | SM Page | Replace With Bulletin Page |
EVAP Pressure/Purge Diagnostic Cart Test Procedure | 193 | 8 |
DTC P0440 | 195 | 4 |
DTC P0442 | 197 | 5 |
2000 - 2002 S-Series Engine Service Manuals | ||
Flowchart/Procedure To Be Replaced | SM Page | Replace With Bulletin Page |
DTC P0440 | 235 | 4 |
DTC P0442 | 237 | 5 |
EVAP Pressure/Purge Diagnostic Cart Test Procedure | 343 | 8 |
200 L-Series (L61) Engine Service Manuals | ||
---|---|---|
Flowchart/Procedure To Be Replaced | SM Page | Replace With Bulletin Page |
DTC P0440 | 207 | 6 |
DTC P0442 | 209 | 7 |
EVAP Pressure/Purge Diagnostic Cart Test Procedure | 322 | 8 |
2001 L-Series (L61) Engine Service Manuals | ||
Flowchart/Procedure To Be Replaced | SM Page | Replace With Bulletin Page |
DTC P0440 | 207 | 6 |
DTC P0442 | 209 | 7 |
EVAP Pressure/Purge Diagnostic Cart Test Procedure | 328 | 8 |
2002 L-Series (L61) Engine Service Manuals | ||
Flowchart/Procedure To Be Replaced | SM Page | Replace With Bulletin Page |
DTC P0440 | 225 | 6 |
DTC P0442 | 229 | 7 |
EVAP Pressure/Purge Diagnostic Cart Test Procedure | 340 | 8 |
New Flowchart To Be Replaced | Location To Insert New Flowchart |
---|---|
DTC P0442 | Insert bulletin page 7 between 300 and 301. |
DTC P0455 | Insert bulletin page 6 between 322 and 323. |
2001 L-Series (L81) Engine Service Manuals | |
New Flowchart To Be Replaced | Location To Insert New Flowchart |
DTC P0442 | Insert bulletin page 7 between 306 and 307. |
DTC P0455 | Insert bulletin page 6 between 326 and 327. |
2002 L-Series (L81) Engine Service Manuals | ||
---|---|---|
Flowchart/Procedure To Be Replaced | SM Page | Replace With Bulletin Page |
DTC P0442 | 323 | 7 |
DTC P0455 | 350 | 6 |
EVAP Pressure/Purge Diagnostic Cart Test Procedure | 455 | 8 |
2002 VUE Powertrain Electrical Diagnostic Service Manuals | ||
---|---|---|
Flowchart/Procedure To Be Replaced | SM Page | Replace With Bulletin Page |
DTC P0440 (L61) | 145 | 4 |
DTC P0442 (L61) | 149 | 5 |
EVAP Pressure/Purge Diagnostic Cart Test Procedure | 294 | 8 |
DTC P0440 (L81) | 574 | 4 |
DTC P0442 (L81) | 579 | 5 |
EVAP Pressure/Purge Diagnostic Cart Test Procedure | 739 | 8 |
Service manual update page for DTC P0440 flowchart. Refer to Technical Information Bulletin 01-T-02, January 2002.
Service manual update page for DTC P0442 flowchart. Refer to Technical Information Bulletin 01-T-02, January 2002.
Service manual update page for DTC P0440 and P0455 flowchart. Refer to Technical Information Bulletin 01-T-02, January 2002.
Service manual update page for DTC P0442 flowchart. Refer to Technical Information Bulletin 01-T-02, January 2002.
Service manual update for EVAP Pressure/Purge Diagnostic Cart Test Procedure. Refer to Technical Information Bulletin 01-T-02, December 2001.
Diagnostic Process
ENSURE THAT VEHICLE UNDERBODY TEMPERATURE IS SIMILAR TO AMBIENT TEMPERATURE, AND ALLOW SURROUNDING AIR TO STABILIZE BEFORE STARTING DIAGNOSTIC PROCEDURE.
FLOWMETER TEST
Models | 1998-1999 MY | 2000 MY | 2001 MY | 2002 MY |
S-Series | .040 in | .040 in | .020 in | .020 in |
L-Series | N/A | .040 in | .040 in | .020 in |
VUE | N/A | N/A | N/A | .040 in |
Important: Larger volume fuel tanks, and/or those with lower fuel levels, may require several minutes for floating indicator to stabilize.
• | ABOVE red flag - UNACCEPTABLE (FAIL-return to service information). |
• | BELOW red flag - ACCEPTABLE (PASS-test completed). |
SERVICE BAY TEST
Disconnect nitrogen/smoke hose from vehicle. Install service port cap. Perform EVAP Service Bay Test using a scan tool.
• | If vehicle passes Service Bay Test, testing is complete. |
• | If vehicle does not pass, return to service information. |