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1995 Suzuki Sidekick - LPFET During Smog Test Collapses Fuel Tank

CA smog test collapses fuel tank. 1995 Suzuki Sidekick 16-valve 4x4, 4-speed automatic. LPFET Test.

Two years ago, my 1995 Suzuki Sidekick 16-valve, 4x4, 4-speed automatic passed CA smog at a Gold Shield facility. Afterwards, it had reduced power and the fuel gauge did not work. Neither problem existed before the test. I found low fuel pressure and speculated that both the gauge and pressure problems were a harness problem. I finally pulled the tank and found it badly imploded. The smog test station took no responsibility. I replaced the pump and was able to blow the tank out. There were no leaks afterwards. Two years later (just a few days ago) it went in for the routine test. I saw the mechanic fool around with the pressure test for a long time and he looked under the tank several times. It passed the test but, now, the fuel gauge reads differently and I suspect the tank has been damaged again. I will have to pull the skid plate and, possibly, the tank to make sure. What part of the test could result in a negative pressure on the tank? Is this a common problem with certain vehicles with today's test requirements? What is my recourse?

Answer:

The LPFET (EVAP) test is conducted by a BAR approved Low Pressure Fuel Evaporative Test machine. A pressure hose is connected to your Suzuki Sidekick's gas filler. This is where the gas cap goes. Your Suzuki's EVAP system and gas tank is pressurized 0.5-1.0 psi (14"-28" column of water) and pressure drop measured for 2 minutes. The allowable drop is .40 psi. Anything greater then .40 psi shows a leaking EVAP system. Based on the EVAP testing procedures we can not ascertain how your Suzuki Sidekick's gas tank could have imploded due to the EVAP test. We recommend inspecting the EVAP system for possible blockages and/or an incorrect gas cap. The stock working gas cap should have a vacuum breaker built-in. An incorrect or defective gas cap might cause the problem you are describing. posted by SmogTips Support

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