2007 Suzuki XL7, P0496 & Hard Restart After Fueling

This 2007 Suzuki XL7 came in with the SES light on and an odd complaint that the engine would not restart after refueling. The customer stated that she had learned that if she depressed the gas pedal about 25% to 50% the engine would fire up and run. That solution would suggest a problem with either too much fuel or not enough air at closed throttle. I checked codes and there was only one code stored, P0496, Evaporative Emission System High Purge Flow. That code along with the vehicle complaint solidified the diagnosis of too much fuel at closed throttle on a warm restart.


To further diagnose the problem the Canister purge solenoid assembly would have to be removed. It is located at the rear bank of the engine. The engine cover will need to be removed to remove the canister purge solenoid for testing.


The oil filler cap needs to be removed. If possible the area should be blown free of any debris before removing the cap.


I try to make sure no debris has made it into the oil fill hole and then put a clean shop towel into the hole while it is left open.


Then the engine cover or finish panel can be lifted up and off of the engine. There are two rubber detent washers that attach it to two posts on the driver’s side of the engine.


The canister purge solenoid is located as shown below between the coils and the upper intake.



There is a thumb latch that has to be depressed on the harness connector before it can be removed.



There is a lever latch that has to be released on the passenger side hose before the hose can be pulled from the solenoid assembly.



Closed position secures the hose to the solenoid tube.



Open position for removal of the hose from the solenoid.


The hose on the driver’s side has a white bar that has to be depressed.



Before the hose can be pulled loose.



The mechanism released and in the lock position to keep it secured to the solenoid.



The bar fully depressed so that the lock is released.



A single bolt with a 10mm head holds the canister purge solenoid assembly to the intake.



The old part on the left and the new one on the right. By the way, the test to see if it is faulty is to just simply blow through the solenoid. If you can blow through it, it is no good. If you cannot then it is at least good from a sealing perspective. The resistance across the two terminals was 17.2 Ω / ohms.



The new canister purge solenoid assembly installed.


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