1998 Chevrolet Cavalier Z24, 2D Convertible, StandardFACTORY OEM SERVICE PROCEDURE

Diagnostic Procedures

  1. Perform POWERTRAIN ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK  , then go to next step.
  2. If DTC P0452, P0453 or P0460 is also set, go to that DTC first. If not, go to next step.
  3. Check fuel cap for missing or loose condition. Repair or replace as necessary. After repairs, go to step 19). If repair is not necessary, go to next step.
  4. Turn ignition on, with engine off. Using scan tool, command EVAP canister purge valve and EVAP vent solenoid on and off. If purge valve and vent solenoid click, go to next step. If purge valve and/or vent solenoid do not click, diagnose PCM.
  5. Turn ignition off. Disconnect purge line from fuel tank at EVAP canister. Turn ignition on, engine off. Using scan tool, observe fuel tank pressure sensor value. If scan tool reads 0 mm Hg, go to step 7). If scan tool does not read 0 mm Hg, go to next step.
  6. Check if EVAP purge line from fuel tank to EVAP canister is pinched, kinked or plugged. Repair or replace as necessary. After repairs, go to step 20). If purge line is okay, diagnose system using DTC P0452 or P0453 tests.
  7. Reconnect all EVAP hoses that was disconnected. Using scan tool, command EVAP vent solenoid on (closed). Connect the EVAP Pressure/Purge Diagnostic Station (J 41413) to EVAP service port. Attempt to pressurize EVAP system to 5 in. H2O while holding EVAP Pressure/Purge Diagnostic Station in HOLD position. If specified pressure is obtained, go to next step. If specified pressure cannot be obtained, go to step 10).
  8. Maintain EVAP system pressure at 5 in. H2O. Using scan tool, observe FUEL TANK VACUUM PRESSURE. If pressure reading is 3-7 in. H2O, go to step 12). If pressure reading is not 3-7 in. H2O, go to next step.
  9. Turn ignition off. Install Fuel Tank Cap Adapter (J 41415-40). Connect EVAP Pressure/Purge Diagnostic Station (J 41413) to fuel tank cap adaptor. Turn ignition on, engine off. Using scan tool, command EVAP vent solenoid on. Using EVAP pressure/purge diagnostic station, pressurize EVAP system to 15 in. H2O. Monitor pressure for 2 minutes. If pressure drops to less than 10 in. H2O, go to next step. If pressure does not drop to less than 10 in. H2O, go to step 14).
  10. Disconnect fuel tank vapor and EVAP purge hoses from EVAP canister. Plug canister fitting for fuel tank vapor hose. Ensure EVAP vent solenoid is still commanded on. Connect a hand-held vacuum pump to EVAP purge hose fitting on EVAP canister and apply 5 in. Hg. If vacuum holds, go to step 15). If vacuum does not hold, go to step 14).
  11. Check for restricted fuel tank vapor and EVAP purge hoses. Repair as necessary. After repair is completed, go to step 20). If hoses are okay, diagnose fuel tank pressure sensor using DTC P0452 or P0453 tests.
  12. Disconnect vacuum hose at EVAP canister purge valve (from throttle body). Connect a hand-held vacuum pump to EVAP canister purge valve vacuum source fitting. Apply 10 in. Hg. Using scan tool, command EVAP canister purge valve on. If vacuum is released, go to next step. If vacuum holds, go to step 17).
  13. Connect a vacuum gauge to EVAP canister purge valve vacuum hose (from throttle body). Start engine. Increase engine speed to 2500 RPM. If vacuum is greater than 10 in. Hg, see DIAGNOSTIC AIDS. If vacuum is 15 in. Hg or less, go to step 18).
  14. Check for disconnected or damaged vent hose. Also, check for damaged EVAP canister. Repair as necessary. After repair is completed, go to step 20). If no problem is found, go to step 19).
  15. Check for missing or faulty fuel cap. Check for disconnected or leaking fuel tank vapor hose or disconnected or damaged EVAP purge hose. Repair as necessary. After repairs, go to step 20). If no problem is found, go to next step.
  16. Using scan tool, command EVAP vent solenoid on. With EVAP pressure/purge diagnostic station connected to EVAP service port, attempt to pressurize EVAP system by leaving control knob in PRESSURIZE position. Using Ultrasonic Leak Detector (J-41416), locate and repair EVAP system leak. It may be necessary to partially lower fuel tank to examine hose connections at top of tank. After repair is completed, go to step 20).
  17. Replace EVAP canister purge valve. After replacing purge valve, go to step 20).
  18. Locate and repair cause of low or no vacuum. After repairs, go to step 20).
  19. Replace EVAP vent solenoid. After replacing solenoid, go to next step.
  20. Turn ignition on, with engine off. Using scan tool, command EVAP vent solenoid on (closed). Using EVAP pressure/purge diagnostic station, pressurize EVAP system to 15 in. H2O. Set rotary switch on diagnostic station to HOLD and observe EVAP pressure gauge. If pressure decreases to less than 10 in. H2O within 2 minutes, repeat step 3). If pressure does not decrease to less than 10 in. H2O within 2 minutes, go to next step.
  21. Clear DTCs. Start and warm engine to normal operating temperature. Operate vehicle within conditions for setting this DTC. If scan tool indicates that the diagnostic ran and passed, go to next step. If scan tool does not indicate that the diagnostic ran and passed, repeat step 2).
  22. Using scan tool, check if additional DTCs are set. Diagnose affected DTCs. If no additional DTCs are set, system is okay.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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