DTC P1441 and/or Hard Start or Extended Crank After Adding Fuel #98-T-40 - (Jan 6, 2003)

1998 Saturn vehicles

Condition

The vehicle may exhibit a DTC P1441 and/or hard start or extended crank condition immediately after fuel fill.

Cause

Some EVAP canister purge solenoids may stick open, which may cause the DTC to set and/or a hard start condition immediately after a fuel fill. Fuel vapors generated during a fuel fill may leak past the EVAP canister purge solenoid and into the intake manifold causing this hard start condition.

Correction

Refer to the following procedure to repair this condition.

Procedure

1. Connect a Scan tool to vehicle.
• If using a Tech 2, run the "EVAP Service Bay Test" on EVAP system. Observe the "EVAP CP Valve Leak" status. If "EVAP CP Valve Leak" fails, the EVAP canister purge solenoid may be stuck open.
• If using the PDT, run "EVAP Service Bay" on EVAP system. Observe the "Purge Leak" status. If "Purge Leak" status fails, the EVAP canister purge solenoid may be stuck open.
2. Verify that no DTCs other than P1441 are stored. If any other DTCs are stored, refer to the proper diagnostic chart in the service manual.
3. Position vehicle on hoist and raise vehicle.
4. Disconnect EVAP canister purge solenoid vacuum source (hose to intake manifold), and connect a vacuum tester to the EVAP canister purge solenoid and apply vacuum.
• If the EVAP canister purge solenoid holds vacuum, refer to System Diagnosis in the service manual.
• If the EVAP canister purge solenoid does not hold vacuum, the solenoid is stuck open.
5. Replace the EVAP canister purge solenoid.
1. Disconnect wiring connect from EVAP canister purge solenoid.
2. Disconnect vent line quick connect from EVAP canister purge solenoid.
3. Remove the 10 mm hex head attachment screw from EVAP canister purge solenoid and remove solenoid from vehicle.
4. Install EVAP canister purge solenoid to engine block with 10 mm hex head attachment screw.
5. Connect 90° purge line quick connect (L.H. port) vacuum source hose to EVAP canister purge solenoid.

Important

Make sure that female connector is seated and "click" is heard. Pull back to confirm engagement.

6. Connect wiring harness to EVAP canister purge solenoid.
7. Lower the vehicle.
8. Verify by clearing all DTCs and running the Service Bay Test again on EVAP system.

Parts Requirement

21008078 - EVAP Canister Purge Solenoid

Claim Information

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows:

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer".  They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle.  Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely.  If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition.  See your GM dealer for information on whether your vehicle may benefit from the information.

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