SES Lamp On with DTC P0442 "EVAP System Small Leak Detected" Set (Diagnose Evaporative Emission [EVAP] System, Repair as Necessary) (05-06-04-049)

SES Lamp On with DTC P0442 "EVAP System Small Leak Detected" Set (Diagnose Evaporative Emission [EVAP] System, Repair as Necessary)

TECHNICAL SERVICE BULLETIN

Condition

Some customers may comment that the Service Engine Soon (SES) lamp is illuminated.

Upon further investigation, technicians may find diagnostic trouble code (DTC) P0442 "EVAP Small Leak Detected" set.

Cause

One of several EVAP system component issues may cause a DTC P0442 to set in the PCM and illuminate the SES light.

Correction

Refer to DTC P0442 diagnostic procedures in the appropriate 2000 Saturn S-Series Service Manual or SI (SI Document ID 882724) to diagnose and repair the vehicle as necessary. If there is no concern found, follow the diagnostic steps listed in the "Service Procedure" section of this bulletin and repair as necessary.

Service Procedure

Perform the following inspections and repair, if necessary:

1. Inspect both ends of all EVAP circuits for damaged and/or spread terminal pins.
2. Inspect the coolant temperature sensor connector for corroded, damaged, and/or spread pins.
3. Remove the coolant temperature sensor and inspect the temperature-sensing probe to determine if it is composite (plastic). If so, replace the coolant temperature sensor with a new sensor, which will contain an all-brass temperature-sensing probe. Refer to "Engine Coolant Temperature (ECT) Sensor Replacement" (SI Document ID 883314).
4. Replace the thermostat. Refer to "Thermostat Replacement" (SI Document ID 877509).

Parts Information

Part Number	Description	Qty
21025106	Sensor Asm - Eng Cool Temp	1
21006335	Thermostat Kit - Eng Cool	1

Claim Information

For vehicles repaired under warranty, use:

Labor Operation	Description	Labor Time
J6368	Sensor, Engine Coolant Temperature - Replace	Use Published Labor Operation Time
J3520	Housing and/or Gasket, Thermostat - Replace