Evaporative Emission System Smoke Test

WARNING: Use the nitrogen gas. If other kind of gas is used for the nitrogen gas, the gasoline may ignite and explode.

CAUTION: Do not introduce smoke into any other systems than the evaporative emission system in order to prevent performance degradation of the other systems.

NOTE:

The vehicle battery must be fully charged for optimum tester performance.
It is not recommended to use the tester in an outside repair bay area, because wind and/or bright sunlight could make the tester very difficult to read.

Connect the red battery clip from the tester to the positive battery terminal, then connect the black battery clip from the tester to chassis ground.
NOTE: Completely unwind the nitrogen/smoke hose from the bracket to optimize the tester's performance.
Connect the nitrogen/smoke hose (1) onto the fuel cap adapter (2).
Remove fuel cap, then install fuel cap adapter onto the fuel filler neck.
Install fuel filler cap (3) onto the fuel cap adapter.
NOTE: Connections must be tight and leak-free.

Fig 1: Installing Fuel Filler Cap Onto Fuel Cap Adapter
Courtesy of SUZUKI OF AMERICA CORP.
Turn the ignition switch ON leaving the engine OFF.
WARNING: To prevent personal injury and equipment damage, tests with Evaporative Emission System Tester are performed with the engine OFF.
Close the EVAP canister vent valve as follows.
1. When using SUZUKI scan tool:
  1. Connect SUZUKI scan tool to DLC with ignition switch OFF.
  2. Turn ON ignition switch, clear DTC and select "MISC. TEST" mode on SUZUKI scan tool.
    Special Tool
    1. SUZUKI scan tool
      
      Fig 2: Connecting SUZUKI Scan Tool To DLC With Ignition Switch OFF
      Courtesy of SUZUKI OF AMERICA CORP.
2. When not using SUZUKI scan tool:
  1. Turn ignition switch ON.
  2. Using service wire, ground "G04-5" terminal of ECM connector (valve ON) "B" and unground it (valve OFF) "A".
    
    Fig 3: Identifying Connector Terminal
    Courtesy of SUZUKI OF AMERICA CORP.
Turn the NITROGEN/SMOKE valve (1) on the control panel to SMOKE.

Fig 4: Turning Nitrogen/Smoke Valve On Control Panel
Courtesy of SUZUKI OF AMERICA CORP.
Press and release the remote switch to activate the tester and inject smoke into the EVAP system.
NOTE: The remote switch operates in a push ON, push OFF fashion.
Disconnect EVAP canister purge hose (1) from EVAP canister purge valve (2) and check that smoke comes out of it in order to verify smoke is filled the EVAP system.
NOTE: Inject smoke in less than two-minute cycles for optimum tester performance.

Fig 5: Disconnecting EVAP Canister Purge Hose From EVAP Canister Purge Valve
Courtesy of SUZUKI OF AMERICA CORP.
Press and release the remote switch to deactivate the tester.
Connect EVAP canister purge hose to EVAP canister purge valve.
Introduce smoke into the system for an additional 60 seconds.
Continue introducing smoke at 15 second intervals, as necessary.
NOTE: For optimum visual smoke performance, deactivate the smoke flow and allow the system pressure to drop. Allowing the smoke to exit small holes at a low flow rate greatly enhances visibility.
Using the halogen light (1), 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 needed, until leak source is identified.
If leakage is not found, go to Step 15).

If leakage is found, go to Step 20).

NOTE: Using the ultraviolet light (2) and shield glasses (3) if available, the exact location of the leak can be identified. The Ultra Trace UV(tm), which has been deposited at the exact location of the leak, fluoresces by shinning the ultraviolet light. Once the area of the leak is identified by the exiting smoke, trying this method is helpful when the leak is in an area that is not readily visible.

Fig 6: Inspecting Entire EVAP System Path Light And Look For Source Of Leak Using Halogen Light
Courtesy of SUZUKI OF AMERICA CORP.
Disconnect hose from the outlet nozzle (1) of EVAP leak check module.
Plug outlet nozzle with finger or the rubber plug. The evaporative emission system should be sealed and ready to be tested.
NOTE: In case that the outlet nozzle of the EVAP leak check module, air would be leaked from the nozzle. Because of the leak, there is a possibility of the misdiagnosis.

Fig 7: Disconnecting Hose From Outlet Nozzle Of EVAP Leak Check Module
Courtesy of SUZUKI OF AMERICA CORP.
Prepare to operate EVAP canister purge valve as follows.
1. When using SUZUKI scan tool:
  1. Connect SUZUKI scan tool to DLC with ignition switch OFF.
  2. Turn ON ignition switch, clear DTC and select "MISC. TEST" mode on SUZUKI scan tool.
    Special Tool
    1. SUZUKI scan tool
      
      Fig 8: Connecting Data Link Connector Switch ON
      Courtesy of SUZUKI OF AMERICA CORP.
2. When not using SUZUKI scan tool:
  1. Turn ignition switch to ON position.
  2. Using service wire, ground "C46-30" terminal of ECM connector (valve ON) (2) and unground it (valve OFF) (1).
    
    Fig 9: Checking ECM Connector Terminal
    Courtesy of SUZUKI OF AMERICA CORP.
Disconnect purge hose (1) from pipe in engine room.
Check purge valve for operation and vacuum passage for clog when valve is switched ON and OFF by using SUZUKI scan tool or service wire.
If check result is not described, replace EVAP canister purge valve.

EVAP canister purge valve specification
1. Valve OFF: Smoke should not come out of hose (1) .
2. Valve ON: Smoke should come out of hose (1) .
  
  Fig 10: Identifying EVAP Canister Vent Valve
  Courtesy of SUZUKI OF AMERICA CORP.
Repair the leaks identified.
Perform the pressurization test again referring to EVAPORATIVE EMISSION SYSTEM LEAK INSPECTION (VEHICLE WITH ORVR SYSTEM) and check whether the leak is completely repaired.
Charge the battery as necessary.
NOTE: After the tester has been used in SMOKE mode, smoke may condense inside the nitrogen/smoke hose, turning into an oil.
Over time, this buildup of oil could degrade the performance of the tester. Use the following procedure any time the tester has been used in SMOKE mode and will be set aside for a long period of time.
1. Close the valve on the nitrogen tank.
2. Disconnect the nitrogen/smoke hose from the vehicle.
3. Turn the NITROGEN/SMOKE valve to NITROGEN.
4. Press and release the remote switch to activate the tester and purge any residual smoke from the nitrogen/smoke hose.