Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Evaporative Canister

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SERVICING



The evaporative (charcoal) canister, known as the vapor storage canister, is a part of the evaporative emission control system. The canister stores fuel vapors when the engine is not running for later use. Inspect the canister periodically, and it should be replaced with a new one every 97,500 miles (162,500 km) or 8 years, whichever occurs first, regardless of its condition.

The evaporative (charcoal) canister is mounted in the engine compartment, near the air cleaner housing.

To inspect and replace the canister, perform the following:

1986-89 Samurai Models

See Figure 1


WARNING
Never suck on the evaporative (charcoal) canister nipples, because the fuel vapors contained within the canister are extremely toxic and harmful.

  1. Disconnect the negative battery cable to prevent accidental sparks, which can ignite fuel vapors.
  2.  
  3. Label and detach all of the hoses from the canister, then remove the canister from its mounting bracket.
  4.  
  5. To test and inspect the canister, perform the following:
    1. Plug canister nipples C and D with your fingers (refer to the accompanying illustration), then blow air into nipple A strongly. Air should emit from nipple B .
    2.  
    3. Unplug the other nipples, then blow air into nipple B ; no air should pass out of nipples A , C or D .
    4.  
    5. Blow air into nipple C ; air should exit from the other 3 nipples.
    6.  
    7. Inspect the canister and related hoses for damage, such as cracks, holes, deterioration, etc.
    8.  
    9. If the canister does not function as stated or exhibits physical damage, it is defective and needs to be replaced with a new one.
    10.  

  6.  



Click image to see an enlarged view

Fig. Fig. 1: Evaporative (charcoal) canister component identification-1986-89 Samurai models

To install:
  1. Insert the canister into its mounting bracket and attach the hoses to the canister.
  2.  
  3. Connect the negative battery cable.
  4.  

Except 1986-89 Samurai Models

See Figures 2 and 3


WARNING
Never suck on the evaporative (charcoal) canister nipples, because the fuel vapors contained within the canister are extremely toxic and harmful.



Click image to see an enlarged view

Fig. Fig. 2: The evaporative canister (arrow) is mounted on the inner, right-hand fender

  1. Disconnect the negative battery cable to prevent accidental sparks, which can ignite fuel vapors.
  2.  
  3. Label and detach all of the hoses from the canister, then remove the canister from its mounting bracket.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: Evaporative (charcoal) canister component identification-except 1986-89 Samurai models



Click image to see an enlarged view

Fig. Fig. 4: Evaporative canister inlet and outlet nipple identification-except 1986-89 Samurai models

  1. To test and inspect the canister, perform the following:
    1. Plug canister nipples C with a finger (refer to the accompanying illustration), then blow air into nipple A strongly; air should emit from nipple B .
    2.  
    3. Unplug the other nipples, then blow air into nipple B ; no air should pass out of nipples A or C .
    4.  
    5. Blow air into nipple C ; air should exit from the other 2 nipples.
    6.  
    7. Inspect the canister and related hoses for damage, such as cracks, holes, deterioration, etc.
    8.  
    9. If the canister does not function as stated or exhibits physical damage, it is defective and needs to be replaced with a new one.To install:
    10.  

  2.  
  3. Insert the canister into its mounting bracket and attach the hoses to the canister.
  4.  
  5. Connect the negative battery cable.
  6.  

 
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