Service Engine Soon (SES) Lamp Illuminated with Diagnostic Trouble Code (DTC) P0496 Set and/or Hard Start or Extended Crank After Adding Fuel (Replace EVAP Canister Purge Solenoid Valve)

Some customers may comment on a SES lamp illuminated (with DTC P0496 set) and/or a hard start or an extended crank condition immediately after fuel fill. Some customers may also comment on vehicle drivability concerns or poor idle quality after fuel fill.

Some evaporative emission (EVAP) canister purge solenoid valves may intermittently 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 a hard start condition. If the evaporative emission (EVAP) canister purge valve does not seal properly, fuel vapors could enter the engine at an undesired time, causing drivability concerns.

The control module tests for a stuck EVAP canister purge solenoid valve by commanding the EVAP canister purge valve OFF, closed; and vent valve ON, closed; sealing the system, and monitoring the fuel tank pressure (FTP) sensor for an increase in vacuum. If the control module detects that EVAP system vacuum increases above a calibrated value, DTC P0496 may set.

Replace the EVAP canister purge solenoid valve. Refer to "Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement" procedure in the Engine Controls - 3.5L (L66) section of the 2004 Saturn VUE Service Manual, Vol. 1 (SI Document ID #1275856).

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for J6400 (Solenoid, Evaporative Emission Canister Purge - Replace).