DTC P0441: EVAP System Incorrect Purge Flow, DTC P0442: EVAP System Leak Detected (Small), Or DTC P0455: EVAP System Leak Detected (Large): Procedure
NOTE:
If any DTC(s) present or pending are related to MAF, ECT, FLS, IAT, DMTL or PSV repair those first. Using scan tool, clear DTCs. Drive vehicle with Hi-Scan Pro/Kia Data Pro scan connected to OBD-II Data Link Connector (OBD-II DLC) and monitor for pending codes. If DTC P0441, P0442 or P0445 returns, perform following procedure.
- Inspect the fuel cap has its o-ring seal installed and is in good condition. Verify cap releases pressure/vacuum at specified value (about 2 psi pressure and 1.5 inches of mercury vacuum). If Fuel cap is in good working condition, go to next step. Fuel cap is not in good working condition, replace the fuel cap.
- Inspect fuel filler pipe for cracks or damage inspect o-ring seat for deformation. If filler pipe is okay, go to next step. Filler pipe is damaged, replace fuel filler pipe.
- Remove PSV and supply battery voltage to one terminal and negative to the other terminal. A slight clicking noise should be heard from the PSV. With light pressure blow air into one of the ports, see Fig 1 . Check that air escapes from other port when energizing and de-energizing PSV. Purge solenoid valve is working properly, go to next step. PSV is not working properly, replace with known good PSV. If problem is corrected, replace PSV.
- Install PSV and thoroughly check all fuel vapor lines and hose clamps between:
- Canister and rollover valve
- Canister and ORVR valve
- Canister and catcher tank
- Canister and DMTL
- Catcher tank and PSV
- PSV and intake manifold
- Verify arrow on PSV is pointing towards intake manifold. If it is not, reverse its installation.
With system sealed and pressurized, check for leaks with a R134a leak detector. Vapor hoses and clamps are not okay, replace all cracked/damaged hoses or loose clamps. If vapor hoses and clamps are okay, temporarily install a good known DMTL and check for proper operation. If problem is corrected, replace DMTL and go to next step.
- Return vehicle to original condition. Verify repairs are complete.