Code P0496 - Evap system error

[Nightwalker]

So yeah, my Astra started to sound like death when the A/C was turned on, but ok with it off.

I just let it be due to a lack of free time at the moment, but my check engine light came on this morning.

A quick scan revealed code P0496 - "Evaporative Emission System High Purge Flow"

Pretty much some valve is going crazy and the car isn't too happy.

Does any one have a diagram of where the evap system components (or better yet, the valve in question) are located under the hood? Thanks.

[Astra La Vista!]

No diagram, but according to my Haynes:

"On 1.4, 1.6, and 1.8 litre Z18XER (ours) engines, the purge valve is mounted on the inlet manifold (see illustration)."

Unfortunately, the illustration has the caption "Typical purge valve location" and I'm nowhere near my car so I can't tell if the pic matches what is under the hood. If I had to guess, it would be near the serpentine belt end. But by definition, the valve is a sort of solenoid, which means it should have an electrical connector as well as two vapour hoses attached to it. That should make it easier to spot. One of those hoses should connect to the charcoal cannister, which is supposedly located behind the R/F wheel fender liner near the bottom door hinge.

[Nightwalker]

Awesome, thank you so much. I'll check it out as soon as I get the chance.

[Nightwalker]

Alright, I jumped under the hood, and I believe that I found the solenoid.

Its on the top of the intake manifold, passenger side like you said. Two hoses (one on each side) and a wire harness on the front of it.

I'm just not 100% sure that it is the correct valve (although I am about 99% sure it is). It has a red w/blue stripe and brown w/white stripe wire harness connected to it.
I found an ecotec forum that had a member with the same problem, and a guy on that form said that the valve had a red/blue wire going to it. My issue about that is not only was it a cobalt, but it had the 2.2L ecotec.

Either way, the P/N for the cobalt's valve is 12597567. I tried to run a search for that number for saturns, and nothing came up for the Astra, just the Aura and Vue.

Any ideas on the part number?

How fun, my warranty expired TWO MILES after this happened

[tallNewfie]

It seems a lot of people have the code readers for their cars, but how do you know what the code means once you get it? Is there an online database or a manual or something?

I plan on getting one when my car gets near the end of it's warranty, so forgive me for being a nube.

[FooBag]

Originally Posted by Nightwalker

Alright, I jumped under the hood, and I believe that I found the solenoid.

Its on the top of the intake manifold, passenger side like you said. Two hoses (one on each side) and a wire harness on the front of it.

I'm just not 100% sure that it is the correct valve (although I am about 99% sure it is). It has a red w/blue stripe and brown w/white stripe wire harness connected to it.
I found an ecotec forum that had a member with the same problem, and a guy on that form said that the valve had a red/blue wire going to it. My issue about that is not only was it a cobalt, but it had the 2.2L ecotec.

Either way, the P/N for the cobalt's valve is 12597567. I tried to run a search for that number for saturns, and nothing came up for the Astra, just the Aura and Vue.

Any ideas on the part number?

How fun, my warranty expired TWO MILES after this happened

My g/f is out of town in the Astra, so I can't take a look at it to confirm you are looking at the right part. Perhaps you can take a picture? I would place very high odds on the Cobalt evap solenoid being different than the Astra one. Most GM parts are stamped with the part number on them.

Reading on the P0496 code, I don't know for certain that the solenoid on the manifold is your problem. On my Impala and other GM vehicles, this code is set when the EVAP canister valve, normally located by the fuel fill neck. Perhaps Astra La Vista can take a look in his Haynes manual to see if the Astra has this valve.

[Nightwalker]

Originally Posted by tallNewfie

It seems a lot of people have the code readers for their cars, but how do you know what the code means once you get it? Is there an online database or a manual or something?

Most codes are universal, but there are online databases for the codes.

As for pictures, here ya go:

In the engine and unhooked:






Images out of the car:






Numbers on it are:

On the face of it (says Bosch, made in Germany):
0 280 142 430
FGP 55 353 802

The side has:
>CuFe<
>PA66-GF25<

I'm leaning toward it being the valve because I believe it leaks.
I unhooked the 2-wire connector and the left side (connected to the evap. canister) pipe. When I started the car, the valve was still creating a vacuum, which points toward it being the valve. It shouldn't create a vacuum at all.

I know the Astra had an issue with the gas tank filler neck that would throw a code, but I couldn't dig up what code that would set.

[Astra La Vista!]

Originally Posted by FooBag

Perhaps Astra La Vista can take a look in his Haynes manual to see if the Astra has this valve.

Nothing mentioned. It is, after all, just a Haynes.

[FooBag]

Originally Posted by Nightwalker

I'm leaning toward it being the valve because I believe it leaks.
I unhooked the 2-wire connector and the left side (connected to the evap. canister) pipe. When I started the car, the valve was still creating a vacuum, which points toward it being the valve. It shouldn't create a vacuum at all.

Your logic sounds good, but one other thing to check is that perhaps the valve is normally open and only closes when commanded through the wiring? Seems like it would be the opposite, but it's worth checking before buying the wrong part.

[Nightwalker]

I didn't exactly come up with that test on my own, the process is in an FSM for another GM vehicle, and the system works the same.

I also checked if the valve could hold a vacuum, which it can't, so it does in fact leak, pointing me toward it being truly defective.

Now, if the valve alone is the only problem or if there is something else busted too, I have no idea. I'm going to just get a new valve, and go from there. I believe its no more than $40, and thats the dealership price!

[Nightwalker]

I ran by the dealership today. As expected, it wasn't in stock.

Good thing, because they wanted nearly $110 for the damned thing!
Talk about price gouging.


I did get the P/N, its 55562350 if anyone cares.
I found it for about $55 from a website on the net, so I think they'll get my business.

[JAC]

You said your warranty was expired, but know that emissions systems components are warranted longer than the 3yr/36,000 standard warranty. Not sure how long but it is significantly longer. You will probably have to argue with the dealer, but they should fix it.

[Nightwalker]

Yes, some parts are, but not the valve in question. The Astra's owner manual has a list of things covered by different warranties, and the valve isn't listed under the emission section.

If this doesn't fix the problem, I will take it to the dealership.

[Nightwalker]

Just to update you all, I got the valve in, swapped it out and put about 100 miles on the car. The code cleared itself and hasn't come on since. So I'm pretty sure that was the issue.

[SCM381]

What website are you finding these parts on? I'm having a hard time finding them.

[MoparNut]

Nightwalker, you said your car sounded 'like death' with the a/c on. What kind of noise, exactly? If it is a screeeching or squealing noise, have you had the revised generator pulley installed?

[Nightwalker]

Originally Posted by SCM381

What website are you finding these parts on? I'm having a hard time finding them.

http://www.gmpartsdirect.com/
I didn't browse for the part, I just put in the part number and hit search.

Originally Posted by MoparNut

Nightwalker, you said your car sounded 'like death' with the a/c on. What kind of noise, exactly? If it is a screeeching or squealing noise, have you had the revised generator pulley installed?

Well, after getting the valve replaced, I was able to verify that I do in fact also need to get the new pulley.

I've apparently needed one for quite a while, I just figured the horrid noise it made was normal (as considering it's been there a while) and it had no effect on performance.

With the valve going bad, the car would idle rough, and combined with the faulty pulley, it was just amplified.

[SCM381]

Originally Posted by Nightwalker

I didn't browse for the part, I just put in the part number and hit search.

Thank you very much!

[red86]

I just received this exact code today, but my engine will actually shut off while idling at a full stop. If i put the Astra back into park and crank it again then it'll start right back up. Any ideas?