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Old 08-05-2017, 09:14 AM   #1
ddemier7
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2004 ION-1 Sedan
Question check engine light came on. Evap code

My 2004 Saturn ion with 204,000 miles the check engine light came on . I went to Oreilly's and had a code scan done and it was the dreaded fuel cap Evap code. I inspected the gas cap and it did have cracks in the O-ring on the fuel cap. I bought a factory OEM replacement fuel cap and installed it correctly (until it clicks). My check engine light is still on? should this eventually go off or do I need to turn it off and reset it? any ideas?

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Old 08-05-2017, 10:21 AM   #2
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Default Re: check engine light came on. Evap code

I found this post on Redline Forums so part numbers may not match but this is some good information that could relate to our Ion's.


"I wanted to post all my info/sources I used here in case anyone else has any issues with this."

Revamp on what happen - This summer the CEL Turned on, well the Dash would Blink/Bing "Check Gas Cap"
I replaced the gas cap two times nothing worked.

I finally took it to the dealership and they told me it was the Fuel Pressure Sensor. 1 Week Later it was doing it again.

I finally did some research on it and this is what I came up with:

-----------------
I want to post this for everyone to see: This is a Check list I guess of everything I went though:

CHECK GAS CAP MESSAGE
The powertrain control module (PCM) sends a class 2 message to the driver information center (DIC) illuminating the Check Gas Cap message when any of the following occur:

* A malfunction in the evaporative emission (EVAP) system and a large leak test fails
* A malfunction in the EVAP system and a small leak test fails

----------------------------

EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM DESCRIPTION

EVAP SYSTEM OPERATION
The evaporative emission (EVAP) control system limits fuel vapors from escaping into the atmosphere. Fuel tank vapors are allowed to move from the fuel tank, due to pressure in the tank, through the vapor pipe, into the EVAP canister. Carbon in the canister absorbs and stores the fuel vapors. Excess pressure is vented through the vent line and EVAP vent solenoid valve to the atmosphere. The EVAP canister stores the fuel vapors until the engine is able to use them. At an appropriate time, the control module will command the EVAP purge solenoid valve ON, allowing engine vacuum to be applied to the EVAP canister. With the EVAP vent solenoid valve OFF, fresh air is drawn through the vent solenoid valve and the vent line to the EVAP canister. Fresh air is drawn through the canister, pulling fuel vapors from the carbon. The air/fuel vapor mixture continues through the EVAP purge pipe and EVAP purge solenoid valve into the intake manifold to be consumed during normal combustion. The control module uses several tests to determine if the EVAP system is leaking.

Large Leak Test
This tests for large leaks and blockages in the evaporative emission (EVAP) system. The control module commands the EVAP vent solenoid valve ON and commands the EVAP purge solenoid valve ON, with the engine running, allowing engine vacuum into the EVAP system. The control module monitors the fuel tank pressure (FTP) sensor voltage to verify that the system is able to reach a predetermined level of vacuum within a set amount of time. The control module then commands the EVAP purge solenoid valve OFF, sealing the system, and monitors the vacuum level for decay. If the control module does not detect that the predetermined vacuum level was achieved, or the vacuum decay rate is more than a calibrated level on 2 consecutive tests, DTC P0455 will set.

Small Leak Test
The engine off natural vacuum (EONV) diagnostic is the small-leak detection diagnostic for the evaporative emission (EVAP) system. While previous leak detection methods were performed with the engine running, the EONV diagnostic monitors the EVAP system pressure or vacuum with the ignition OFF. Because of this, it may be normal for the control module to remain active for up to 40 minutes after the ignition is turned OFF. This is important to remember when performing a parasitic draw test on vehicles equipped with EONV.

The EONV utilizes the temperature changes in the fuel tank immediately following a drive cycle to use the naturally occurring vacuum or pressure in the fuel tank. When the vehicle is driven, the temperature rises in the tank. After the vehicle is parked, the temperature in the tank continues to rise for a period of time, then starts to drop. The EONV diagnostic relies on this temperature change and the corresponding pressure change in a sealed system, to determine if an EVAP system leak is present.

The EONV diagnostic is designed to detect leaks as small as 0.51 mm (0.020 in) . The diagnostic can determine if a small leak is present based on vacuum or pressure readings in the EVAP system. When the system is sealed, a finite amount of pressure or vacuum will be observed. When a 0.51 mm (0.020 in) leak is present, often little or no pressure or vacuum is observed. If the test reports a failing value, DTC P0442 will set.

Canister Vent Restriction Test
If the evaporative emission (EVAP) vent system is restricted, fuel vapors will not be properly purged from the EVAP canister. The control module tests this by commanding the EVAP purge solenoid valve ON, commanding the EVAP vent solenoid valve OFF, and monitoring the fuel tank pressure (FTP) sensor for an increase in vacuum. If the vacuum increases more than a calibrated value, DTC P0446 will set.

Purge Solenoid Valve Leak Test
If the evaporative emission (EVAP) purge solenoid valve does not seal properly fuel vapors could enter the engine at an undesired time, causing driveability concerns. The control module tests for this by commanding the EVAP purge solenoid valve OFF and the vent solenoid valve ON, sealing the system, and monitors the fuel tank pressure (FTP) for an increase in vacuum. If the control module detects that the EVAP system vacuum increases above a calibrated value, DTC P0496 will set.

--------------------------

EVAP SYSTEM COMPONENTS
The evaporative emission (EVAP) system consists of the following components:

EVAP Canister
The canister is filled with carbon pellets used to absorb and store fuel vapors. Fuel vapor is stored in the canister until the control module determines that the vapor can be consumed in the normal combustion process.

EVAP Purge Solenoid Valve
The EVAP purge solenoid valve controls the flow of vapors from the EVAP system to the intake manifold. The purge solenoid valve opens when commanded ON by the control module. This normally closed valve is pulse width modulated (PWM) by the control module to precisely control the flow of fuel vapor to the engine. The valve will also be opened during some portions of the EVAP testing, allowing engine vacuum to enter the EVAP system.

EVAP Vent Solenoid Valve
The EVAP vent solenoid valve controls fresh airflow into the EVAP canister. The valve is normally open. The control module commands the valve ON, closing the valve during some EVAP tests, allowing the system to be tested for leaks.

Fuel Tank Pressure Sensor
The fuel tank pressure (FTP) sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-Volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts . A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure.

EVAP Service Port
The EVAP service port is located in the EVAP purge pipe between the EVAP purge solenoid valve and the EVAP canister. The service port is identified by a green colored cap.

---------------

So what the "Check Gas Cap" error message came down to is one of 4 things.

Bad Gas Cap - So I replaced it. No Fix.
Bad Fuel Pressure Sensor - Replaced. No Fix.
EVAPORATIVE EMISSION (EVAP) CANISTER - Did not replace - I had read on the internet that these things usually do not ever go bad.
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE SOLENOID VALVE - Replaced this, and the Check Engine Light Turned off... FINALLY!

So I think if your having this issue Chances are your Fuel Pressure Sensor is bad, or Your Evap Canister Purge Solenoid Valve is bad. The replacement for this (New)
Purge Solenoid - Part# 12581349 $28.60
Vent Control Solenoid - Part# 15788844 $34.44

Purge Solenoid - Part# 12581349 has been replaced by 12597567

I found some AC Delco numbers:
215-560 / 15214181 Evaporative Emission Canister
214-1680 / 12597567 Evaporative Emission Canister Purge Solenoid Valve
214-2230 / 25932573 Evaporative Emission Canister Solenoid

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Old 09-04-2017, 05:42 PM   #3
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Thumbs Up Re: check engine light came on. Evap code

After replacing gas cap with a OEM gas cap , I reset the codes and about a week later the check engine light came back on. Come to find out my Vapor Canister Purge Solenoid has cracked in half (this part is located on the drivers side upper engine by the oil cap). The spout that connects the vacum line hose that goes to the charcoal canister has cracked in half and failed. I had to locate the vacum hose that was dangaling in the engine bay and reconnected it to the new Purge Solenoid. I will reset codes and go from here.

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Old 09-28-2017, 01:24 AM   #4
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Happy Re: check engine light came on. Evap code

Code went off by itself after replacing part. Yayy

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Old 09-28-2017, 03:09 PM   #5
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1999 SL2
Default Re: check engine light came on. Evap code

All good knowledge. Thank you for sharing with us.

Time for a party!

...
Peter in Lansing MI

current cars:
94 SW2 (White, automatic)
99 SL2 (Silver Plum, manual)
99 SL2 (Dark Blue, manual)
04 Ion 3 (Berry Red, 2.0L automatic)
07 Ion 3 (Cypress Green, 2.4L, manual)

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Old 09-28-2017, 04:18 PM   #6
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Default Re: check engine light came on. Evap code

Quote:
Originally Posted by ddemier7 View Post
Code went off by itself after replacing part. Yayy
great. unrelated question: does yours burn oil with that many miles? i vaguely remember you mentioned that in the past.

...
fixed/replaced so far: side mirror, window trims x4, trunk floor, radiator bushing, alternator, starter, LCA x2, sway bar bushings x2, end links x2, timing chain tensioner, O2 sensor.

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Old 09-30-2017, 12:24 AM   #7
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Wrench Re: check engine light came on. Evap code

Yes mine does burn a little oil but also still drips some under the car. So I just check my oil regularly and add as needed. Just drive it until it blows up. Lol. Good running car tho!

Hope this thread helps somone.

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Old 09-30-2017, 12:07 PM   #8
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Default Re: check engine light came on. Evap code

my son is not good about checking oil. when he showed up back from school, it was 2qts low. he swears he checked it and it was full before he drove. maybe he does it wrong. I need to school him more on that. other than that, the car is surprisingly reliable and he put over 20,000 miles on it without a major drama (or a major accident). we put a lot of work in this POS when we got it, though.

how about that sludge in your engine. how did you fix that?

...
fixed/replaced so far: side mirror, window trims x4, trunk floor, radiator bushing, alternator, starter, LCA x2, sway bar bushings x2, end links x2, timing chain tensioner, O2 sensor.

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Old 10-01-2017, 06:29 PM   #9
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Default Re: check engine light came on. Evap code

These 2.2 ecotec engines are notorious for some oil consumption at our kinda milage so he needs to check it regularly. Only thing I did was run some Marvel Mystery Oil through it and changed the oil at recomended intervals. Im just gona wait until the engine dies before I worry any more about engine sludge. It runs awsome and it too is low maintenance so lets just hope it stays that way.

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