SPECIAL TOOLS BULLETIN

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Lora Harmon
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SPECIAL TOOLS BULLETIN Title: "LEAK MASTER" EVAP SYSTEM "SMOKE" MACHINE Supersedes the April 15, 2004 edition Car Market: NORTH AMERICA : 1 of 5 YEAR MONTH DAY 2004 06 18 INTRODUCING THE LEAKMASTER

1 SPECIAL TOOLS BULLETIN Title: "LEAK MASTER" EVAP SYSTEM "SMOKE" MACHINE Supersedes the April 15, 2004 edition Car Market: NORTH AMERICA : 1 of 5 YEAR MONTH DAY INTRODUCING THE LEAKMASTER J A! The Leak Master is one of the most useful, and simple to operate Evaporative Emissions (EVAP) System Diagnostic Tester available today. It provides a state of the art, fast and effective method for EVAP system leak detection enabling you to pinpoint even the smallest leaks quickly and easily so a problem can be fixed right, first time and that means customer satisfaction. Volvo Car Corporation in Gothenburg, Sweden has tested and approved the Leak Master J A. The machine's state of the art electronics precisely control the critical pressure and flow rates needed for testing Volvo's advanced OBD-II EVAP systems which operate at very low pressure. Standard smoke machines operate at higher pressures and can possibly damage EVAP system components. Not all smoke machines on the market are EVAP system testers equipped with a flow meter, ultraviolet dye, and calibrated to detect and locate EVAP leaks as small as 1mm and.5mm. Although developed specifically to diagnose and locate EVAP system leaks, the versatile LeakMaster will also find intake manifold leaks, exhaust system leaks, under-dash vacuum system leaks, other closed system leaks as well as pinpointing water and wind leaks entering the vehicle's passenger compartment. The LeakMaster can be used on all vehicle makes. Consult the comprehensive LeakMaster Operator's Manual for testing instructions and procedures. HOW TO ORDER: Order a Leak Master J A from SPX. Call "Fixed Right First Time" Service Personnel: read and initial. SERVICE MANAGER PARTS MANAGER WORKSHOP FOREMAN SERVICE TECHNICIANS 2004 Volvo Cars of North America, LLC Printed in USA on recycled paper containing a minimum of 50% wastepaper and 10% post-consumer waste.

2 2 of 5 FEATURES/BENEFITS 1. Flow Meter: The J A Leak Master features a flow meter which allows a quick check and diagnosis of EVAP system leaks and restrictions. Flow meter is active during both testing phases. 2. Control Valve: 1mm and.5mm standards are automatically calibrated internally by a turn of the control valve. 3. Future EVAP Standards: Control valve has a position for "future" EVAP standard should EPA and CARB standards become more stringent. A simple field retrofit is all that will be needed. 4. Accessories: The LeakMaster comes with 2 exhaust cones, cap plugs, 2 EVAP service port fittings for other vehicle makes, nitrogen coil-hose, and halogen light. 5. Ultra-TraceUV Solution: The LeakMaster comes equipped with full charge of non-toxic and non-corrosive smoke producing Ultra-TraceUV solution which will last approximately 1,000 tests before a smoke solution refill is required. 6. Remote on/off switch. 7. Internal Controls: An advanced microprocessor logic-board with sophisticated heater temperature controls to optimize smoke quality. 8. Self Test: Unit comes with oil dipstick, low-oil warning light, and built in trouble codes technology to help identify any problems with the unit. 9. Calibration: The LeakMaster is self-calibrating. 10. Maintenance: The LeakMaster requires an annual smoke solution change. All tests performed with the LeakMaster are performed with the vehicle engine OFF.

3 3 of 5 Component Description Supply Hose: Use when confirming the integrity of an EVAP system, when verifying any system for leaks, or when introducing smoke into a system being tested for leaks. Selector Switch: Use to select the functions of the tester as explained in this manual. Flow Meter: Use its pointer-flag to establish a quick Pass / Fail when determining if the vehicle being tested has a.040 or.020 leak. Water Separator / Filter (on back of tester): Ensures a clean supply of nitrogen or air. Power Indicator Light: Turns on when connecting the power leads to a battery, indicating good contact.

4 4 of 5 Diagnostic Smoke Indicator Light: Turns on after pressing the remote starter button, indicating smoke production. (There is a five second delay before the light comes on.) Remote Starter & Power Cables: Use to operate the tester. The tester stays ON for five (5) minutes after the remote button is pressed; press the button again to turn the tester OFF. Oil Dipstick/Drain/Fill Area (located on the top-back of the tester): Much like a motor oil dipstick, there are low and high marks engraved on the tester's dipstick. Remove the dipstick to maintain the smoke solution level at the FULL mark, and to drain and replace the smoke solution during yearly maintenance service.

5 5 of 5 DIAGNOSTIC SMOKE MACHINES -- FEATURE COMPARISON Between General Purpose Smoke Machines and EVAP-Approved Smoke Machines Features EVAP Approved Smoke Machines Non-EVAP General Purpose Smoke Machine 1 Technology developed in association with G.M., DaimlerChrysler & Ford Motor Co. for specifically testing of vehicle s EVAP systems 2 Specifically built to meet major automakers EVAP testing specifications 3 Specifically designed for testing and diagnosing of all OBD-II systems. Will also test and diagnose OBD-I and pre-obd EVAP systems 4 Auto-pressure design automatically regulates and maintains 13 inch water column pressure required for enhanced OBD-II EVAP testing -- no pressure adjustment option, minimizing the possibility of over-pressurizing EVAP system 5 2-minute quick-pass / fail feature verifies EVAP integrity by confirming if vehicle has a or leak 6 Verifies and finds leaks much smaller than allowing the unit to keep pace with changing test standards 7 Patented smoke solution tested and approved by Big-3. Solution guaranteed not to harm activated charcoal, catalytic converters, O2 sensors, seals or gaskets. 8 Capable of operating with Nitrogen or shop-air 9 Microprocessor-controlled logic 10 UltraTraceUV (in smoke) deposits fluorescent dye at exact leak location(s) 11 Special flow meter verifies leaks and functionality in systems beyond basic EVAP leak testing, such as; testing EVAP purge valve and vent solenoid function, test [generic] solenoid actuation, test HVAC vacuum actuation, etc. 12 General purpose leak detection capabilities; vacuum, wind/water leaks, oil, exhaust, under dash, and other misc. leaks volt operation SPX Leak Master, Part Number J A has been tested and approved by Volvo Car Corporation Rev

LeakTamer. with UltraTraceUV Dye Technology. Operator s Manual

LeakTamer. with UltraTraceUV Dye Technology. Operator s Manual LeakTamer with UltraTraceUV Dye Technology Operator s Manual Table of Contents Table of Contents...1 Safety Precautions...2 Specifications...3 Tester Overview...4 Initial Setup...5 Test Setup...6 Basic