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PostPosted: Thu Oct 18, 2012 5:23 pm 
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Location: Browerville, MN
Year and Trim: 2004 GXP - plus a handful of other Bonnevilles
I am sick of the CEL on Shannon's car. She has the "Check Gap Cap" message and an EVAP code. I've replaced the solenoid, vent valve and pressure sensor. I've checked all the lines and fittings and can't find anything obvious. Using the Tech2, I performed a leak down test of the EVAP and it failed. The next step in the FSM is to use tool J41413 Emissions system test machine, but the machine cost around $1000. The dealer would charge $100+ to perform the test. I decided to make my own smoke machine. There are lots of tutorials on forums and youtube, but I want to show you what I made, and how well it works.

What I used:
old quart sized metal paint can - free, I had this laying around. You should be able to find one for $2-4 at a hardware store.
baby oil (mineral oil) - free, I had this laying around. You should be able to find a small bottle for $2-3 at Walmart.
32 gauge Nichrome wire - $2.99 shipped from ebay
insulted binding posts - $3.19 from RadioShack
mini aligator clips - $3.29 from RadioShack
oil lamp wick - $1.50 from ebay
air regulator - $8.35 shipped on ebay
5/16" clear vinyl tubing 10 feet - I paid $.16 per foot at a hardware store - $1.60
5/16" brass hose barb x 1.4" MIP - $2.69 each from hardware store.
5/16" brass hose barb union - $2.69 from hardware store.
Total cost: $28.99

The whole system runs off a car battery and an air compressor.
Image

This air regulator takes the pressure down to 2-3 psi to slowly move the smoke.
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The paint can has 4 holes drilled in it. 2 on the lid for the hose barb fittings, and 2 on the side for the binding posts.
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Inside the can you can see the aligator clips soldered to the binding posts. This makes it easy to adjust the length of the nichrome wire. The wire is wrapped a few times around the oil lamp wick, which is sitting in a shallow bath of baby oil.
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When you hook up power to the wire, it glows red and the oil on the wick smokes.
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When you put the lid on and run some air through it, you get this:
Image
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Here is a video in action.
http://youtu.be/Rj5pm85nA3o

I can't wait to test this on the car.

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2004 Bonneville GXP | White Gold Tricoat | custom built supercharged 3800 hot rod
2005 Town & Country Limited | Butane Blue Metallic | 270k | Family Hauler
2002 Ram 1500 Quad Cab Sport | Black| 190k | Official Bonneville Hauler


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PostPosted: Thu Oct 18, 2012 5:26 pm 
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Joined: Tue Mar 06, 2012 7:14 pm
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Year and Trim: 98 Pontiac Bonneville SSEi
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PostPosted: Thu Oct 18, 2012 6:13 pm 
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Location: St Cloud, MN
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That is sweet! I don't even need a smoke machine, but I just want to make this to do it!

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PostPosted: Thu Oct 18, 2012 7:45 pm 
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Very nice Andrew.

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PostPosted: Thu Oct 18, 2012 8:46 pm 
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Joined: Mon May 19, 2008 6:04 pm
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Location: Browerville, MN
Year and Trim: 2004 GXP - plus a handful of other Bonnevilles
I hooked up the smoke machine to the car. I filled up the entire system, and smoke was rolling out of the fuel filler area, and the evap vent valve, like it is supposed to. The purge solenoid on the engine is supposed to hold pressure when not powered up, and it had the smallest amount of smoke coming out. I replaced the evap solenoid again, and it didn't leak. I tested the system with the Tech2 and its working perfect. I'm pretty pumped!

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-Andrew-
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2004 Bonneville GXP | White Gold Tricoat | custom built supercharged 3800 hot rod
2005 Town & Country Limited | Butane Blue Metallic | 270k | Family Hauler
2002 Ram 1500 Quad Cab Sport | Black| 190k | Official Bonneville Hauler


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PostPosted: Thu Oct 18, 2012 8:48 pm 
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Location: MN/IA
Year and Trim: '17 Silverado 1500
Glad to hear it. It's definitely a pain to diagnose these issues it seems. Glad my car never had those issues under my ownership...

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RIP sandrock
Sirius wrote:
Think about it. You’re tooling down the road in your Prius, knowing full-well that this thing being green is as big a sham as federally mandated ethanol-enriched gas, Russia pulling out of Ukraine, and Obamacare.


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PostPosted: Thu Oct 18, 2012 9:21 pm 
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Location: Mason City, Ia
Year and Trim: 2004 GXP
That's pretty cool Andrew, nice work!

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PostPosted: Thu Oct 18, 2012 9:43 pm 
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Location: Chicago, IL
Year and Trim: 2003 SLE
That's genius! You have amazing fab skills Andrew.

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PostPosted: Thu Oct 18, 2012 10:59 pm 
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Even the basic smoke kits are crazy expensive.

Nice job on the DIY.

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PostPosted: Fri Oct 19, 2012 12:57 pm 
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Location: Dearborn, MI
Year and Trim: '93 SSEi
'05 STS-4
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'97 LeSabre
Nifty!

I think I might build one of these, my SSEi swap has an evap code set for a leak.

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