Inspection Procedure

NOTE: The hand - held tester is required to conduct the following diagnostic troubleshooting procedure.

HINT:

Using the hand - held tester monitor results enable the EVAP system to be confirmed.
Read freeze frame data using the hand - held tester. Freeze frame data records the engine conditions when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.

CONFIRM DTC
1. Turn the ignition switch OFF and wait for 10 seconds.
2. Turn the ignition switch ON.
3. Turn the ignition switch OFF and wait for 10 seconds.
4. Connect the hand - held tester to the CAN VIM. Thenconnect the CAN VIM to the DLC3.
5. Turn the ignition switch ON.
6. Enter the following menus: DIAGNOSIS / ENHANCEDOBD II/ DTC INFO / CURRENT CODES.
7. Confirm DTCs and freeze frame data.
  If any EVAP system DTCs are set, the malfunctioning area can be determined using the table below.
NOTE: If the 0.02 inch reference pressure difference between the first and second checks is greater than the specification, the DTCs corresponding to the reference pressure (P043E, P043F, P0441, P0455, P0456, P2401 and P2420) will all be stored.

Fig 1: EVAP System DTC Chart
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NEXT
PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
NOTE:
- In the EVAP SYSTEM CHECK (AUTO OPERATION), the series of 5 EVAP SYSTEM CHECK steps are performed automatically. It takes a maximum of approximately 18 minutes.
- Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut-off valve may be closed, making the leak check of the fuel tank not possible.
- Do not run the engine in this step.
- When the temperature of the fuel is 35 °C (95 °F) or more, a large amount of vapor forms and any check results become inaccurate. When performing the EVAP SYSTEM CHECK, keep the temperature below 35 °C (95 °F).
1. Clear the DTCs (See DTC CHECK/CLEAR ).
2. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION.
3. After the EVAP SYSTEM CHECK is completed, check for pending DTCs by entering the following menus: DIAGNOS S / ENHANCED OBD II / DTC INFO / PENDING CODES.
HINT:

If no pending DTC is displayed, perform the Monitor Confirmation after the repair is completed. After this confirmation, check for pending DTCs. If no DTC is displayed, the EVAP system is normal.

NEXT
PERFORM EVAP SYSTEM CHECK (MANUAL OPERATION)

Fig 2: Timing Chart (Perform EVAP System Check)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- In the EVAP SYSTEM CHECK (MANUAL OPERATION), the series of 5 EVAP SYSTEM CHECK steps are performed manually.
- Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut-off valve may be closed, making the leak check of the fuel tank not possible.
- Do not run the engine in this step.
- When the temperature of the fuel is 35 °C (95 °F) or more, a large amount of vapor forms and any check results become inaccurate. When performing the EVAP SYSTEM CHECK, keep the temperature below 35 °C (95 °F).
1. Clear the DTCs (See DTC CHECK/CLEAR ).
2. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / MANUAL OPERATION.
NEXT

PERFORM EVAP SYSTEM CHECK (STEP 1/5)

Fig 3: Timing Chart (Perform EVAP System Check)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 1/5.

Result

RESULT

DTC No. ⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

Virtually no variation in EVAP pressure

Not yet determined

P0451

EVAP pressure fluctuates by +/-0.3 kPa (2.25 mmHg) or more

Canister pressure sensor

HINT:

⁽¹⁾	The DTCs related to the EVAP system are displayed on the intelligent tester when checking.

B: Go to step 30

A: GO TO NEXT STEP

PERFORM EVAP SYSTEM CHECK (STEP 1/5 TO 2/5)

Fig 4: Timing Chart (Perform EVAP System Check)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 1/5 and 2/5.

Result

RESULT

DTC No. ⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

Virtually no variation in EVAP pressure during step 1/5. Then decreases to 0.02 inch leak criterion.

Not yet determined

P2402

Small difference between EVAP pressures during steps 1/5 and 2/5

Leak detection pump stuck ON

HINT:

⁽¹⁾ The DTCs related to the EVAP system are displayed on the intelligent tester when checking.
The first 0.02 inch leak criterion is the value determined in step 2/5.

B: Go to step 23

A: GO TO NEXT STEP

PERFORM EVAP SYSTEM CHECK (STEP 2/5)

Fig 5: Timing Chart (Perform EVAP System Check)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Make a note of the pressures checked in the steps below.

Check the EVAP pressure 4 seconds after the leak detection pump is activated*.
*: The leak detection pump begins to operate as step 1/5 proceeds to step 2/5.
Check the EVAP pressure again when it has stabilized. This pressure is the 0.02 inch leak criterion.

Result

RESULT

DTC No. ⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

EVAP pressure in step (b) between -4.85 kPa and -1.06 kPa (-36.38 mmHg and -7.95 mmHg)

Not yet determined

P043F and P2401

EVAP pressure in step (b) -1.06 kPa (-7.95 mmHg) or more

Reference orifice high-flow

Leak detection pump stuck OFF

P043E

EVAP pressure in step (b) below -4.85 kPa (-36.38 mmHg)

Reference orifice clogged

P2419

EVAP pressure in step (a) more than -1.06 kPa (-7.95 mmHg)

Vent valve stuck closed

HINT:

⁽¹⁾	The DTCs related to the EVAP system are displayed on the intelligent tester when checking.

B: Go to step 11

C: Go to step 30

D: Go to step 19

A: GO TO NEXT STEP

PERFORM EVAP SYSTEM CHECK (STEP 2/5 TO 3/5)

Fig 6: Timing Chart (Perform EVAP System Check)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 3/5.

Result

RESULT

DTC No. ⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

EVAP pressure increases by 0.3 kPa (2.25 mmHg) or more within 10 seconds of proceeding from step 2/5 to step 3/5

Not yet determined

P2420

No variation in EVAP pressure despite proceeding from step 2/5 to step 3/5

Vent valve stuck open (vent)

P0451

No variation in EVAP pressure during steps 1/5 through 3/5

Canister pressure sensor

HINT:

⁽¹⁾	The DTCs related to the EVAP system are displayed on the intelligent tester when checking.

B: Go to step 20

C: Go to step 30

A: GO TO NEXT STEP

PERFORM EVAP SYSTEM CHECK (STEP 3/5)

Fig 7: Timing Chart (Perform EVAP System Check)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Wait until the EVAP pressure change is less than 0.1 kPa (0.75 mmHg) for 30 seconds.
2. Measure the EVAP pressure and record it.
HINT:

A few minutes are required for the EVAP pressure to become saturated. When there is little fuel in the fuel tank, it takes up to 900 seconds (15 minutes).

NEXT

PERFORM EVAP SYSTEM CHECK (STEP 4/5)

Fig 8: Timing Chart (Perform EVAP System Check)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 4/5.

Result

RESULT

DTC No. ⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

EVAP pressure increases by 0.3 kPa (2.25 mmHg) or more within 10 seconds of proceeding from step 3/5 to step 4/5

Not yet determined

P0441

EVAP pressure increases by 0.3 kPa (2.25 mmHg) or more within 10 seconds of proceeding from step 3/5 to step 4/5

Problems in EVAP hose between purge VSV and intake manifold

P0441

Variation in EVAP pressure less than 0.3 kPa (2.25 mmHg) for 10seconds, after proceeding from step 3/5 to step 4/5

Purge VSV stuck closed

HINT:

⁽¹⁾	The DTCs related to the EVAP system are displayed on the intelligent tester when checking.

B: Go to step 15

C: Go to step 12

A: GO TO NEXT STEP

PERFORM EVAP SYSTEM CHECK (STEP 5/5)

Fig 9: Timing Chart (Perform EVAP System Check)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 5/5.
Compare the EVAP pressure in step 3/5 and the second 0.02 inch leak criterion (step 5/5).

Result

RESULT

DTC No. ⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

EVAP pressure (step 3/5) lower than second 0.02 inch leak criterion (step 5/5)

Not yet determined

P0441 and P0455

EVAP pressure (step 3/5) higher than [second 0 02 inch leak criterion on (step 5/5) x 0.2]

Purge VSV stuck open

EVAP gross leak

P0456

EVAP pressure (step 3/5) higher than second 0.02 inch leak criterion (step 5/5)

EVAP small leak

HINT:

⁽¹⁾	The DTCs related to the EVAP system are displayed on the intelligent tester when checking.

A: Go to step 36

B: Go to step 12

PERFORM EVAP SYSTEM CHECK (STEP 3/5)

Fig 10: Timing Chart (Perform EVAP System Check)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 3/5.

Result

RESULT

DTC No. ⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

P043F

EVAP pressure less than [0.02 inch leak criterion] measured at 2/5

Reference orifice high-flow

P2401

EVAP pressure almost same as [0.02 inch leak criterion] measured at 2/5

Leak detection pump stuck OFF

HINT:

⁽¹⁾ The DTCs related to the EVAP system are displayed on the intelligent tester when checking.
The first 0.02 inch leak criterion is the value determined in step 2/5.

A: Go to step 30

B: Go to step 23

PERFORM ACTIVE TEST BY INTELLIGENT TESTER (PURGE VSV)

Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV.
Disconnect the hose (connected to the canister) from the purge VSV.
Turn the ignition switch ON.
Using the tester, turn the purge VSV OFF.
Use your finger to confirm that the purge VSV has no suction.
Using the tester, turn the purge VSV ON.
Use your finger to confirm that the purge VSV has suction.

Fig 11: Disconnecting Hose From Purge VSV

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT

Test Results	Suspected Trouble Areas	Proceed to
No suction when purge VSV turned OFF, and suction applied when turned ON	Purge VSV normal	A
Suction applied when purge VSV turned OFF	Purge VSV stuck open	B
No suction when purge VSV turned ON	Purge VSV stuck closed	C
No suction when purge VSV turned ON	Problems with EVAP hose between purge VSV and intake manifold	C

B: Go to step 14

C: Go to step 15

A: GO TO NEXT STEP

CHECK FUEL TANK CAP

Check that the fuel tank cap is correctly installed and confirm the fuel cap meets OEM specification.
1. Tighten the fuel tank cap until a few click sounds are heard.
HINT:

If an EVAP tester is available, use the tester to check the fuel tank cap.
Remove the fuel tank cap and install it onto the fuel tank cap adaptor.
Connect an EVAP tester pump hose to the adaptor, and pressurize the cap to 3.2 to 3.7 kPa (24 to 28 mmHg) using an EVAP tester pump.
Seal the adaptor and wait for 2 minutes.
Check the pressure. If the pressure is 2 kPa (15 mmHg) or more, the fuel tank cap is normal.

Result

RESULT

Test Results	Suspected Trouble Areas	Proceed to
Fuel tank cap correctly installed	-	A
Fuel tank cap loose	Fuel tank cap improperly installed Defective fuel tank cap Fuel tank cap does not meet OEM specifications	B
No fuel tank cap	-	C

A: Go to step 29

B: Go to step 27

C: Go to step 28

INSPECT PURGE VSV

Turn the ignition switch OFF.
Disconnect the V4 purge VSV connector.
Disconnect the hose (connected to the canister) from the purge VSV.
Turn the ignition switch ON.
Start the engine.
Use your finger to confirm that the purge VSV has no suction.

Fig 12: Inspecting Purge VSV

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT

Test Results	Suspected Trouble Areas	Proceed to
No suction	ECM	A
Suction applied	Purge VSV	B

A: Go to step 35

B: Go to step 31

CHECK PURGE LINE HOSE (PURGE VSV - INTAKE MANIFOLD)

Disconnect the hose (connected to the intake manifold) from the purge VSV.
Turn the ignition switch ON.
Start the engine.
Use your finger to confirm that the hose has suction.

Fig 13: Disconnecting Hose From Purge VSV

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT

Test Result	Suspected Trouble Areas	Proceed to
Suction applied	EVAP hose between purge VSV and intake manifold normal	A
No suction	Intake manifold port EVAP hose between purge VSV and intake manifold	B

B: Go to step 26

A: GO TO NEXT STEP

INSPECT PURGE VSV

Remove the purge VSV connector.
Apply battery voltage to the terminals of the purge VSV.
Using an air gun, confirm that air flows from port A to port B.

Fig 14: Inspecting Purge VSV

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT

Test Result	Suspected Trouble Areas	Proceed to
Air flows	Purge VSV normal	A
No air flows	Purge VSV	B

B: Go to step 31

A: GO TO NEXT STEP

CHECK WIRE HARNESS (POWER SOURCE OF PURGE VSV)

Disconnect the V4 purge VSV connector.
Turn the ignition switch ON.
Measure the voltage between terminal 1 of the purge VSV connector and the body ground.

Fig 15: Disconnecting V4 Purge VSV Connector

Result

RESULT

Tester Connection	Test Results	Suspected Trouble Areas	Proceed to
1 - 2	Between 11 V and 14 V	Normal	A
1 - 2	Other than result above	Wire harness or connectors between purge VSV and ECM	B

B: Go to step 32

A: GO TO NEXT STEP

CHECK WIRE HARNESS (PURGE VSV - ECM)

Disconnect the V4 purge VSV connector.
Disconnect the E5 ECM connector.
Measure the resistance of the wire harness side connectors.

Standard resistance

TESTER CONNECTION SPECIFIED CONDITION

Tester Connection	Specified Condition
V4-1 - E5-11 (PRG)	Below 1 Ω
V4-1 or E5-11 (PRG) - Body ground	10 kΩ or higher

Fig 16: Disconnecting E5 ECM Connector

OK: Go to step 22

NG: Go to step 35

PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FOR VENT VALVE)

Turn the ignition switch ON.
Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VENT VALVE (ALONE).
Measure the voltage between terminal VPMP of the ECM connector and the body ground when the vent valve is turned ON (close) and OFF (vent) using the tester.

Fig 17: Identifying VPMP Terminals

Result

RESULT

Tester Connection	Test Results	Suspected Trouble Areas	Proceed to
E2-12 (VPMP) - Body ground	Below 3 V when OFF and ON	Power source of vent valve	A
E2-12 (VPMP) - Body ground	Between 9 V and 14 V when OFF Below 3 V when ON	Vent valve	B
E2-12 (VPMP) - Body ground	Between 9 V and 14 V when OFF and ON	ECM	C

B: Go to step 22

C: Go to step 35

A: GO TO NEXT STEP

INSPECT CANISTER PUMP MODULE (POWER SOURCE FOR VENT VALVE)

Turn the ignition switch OFF.
Disconnect the C32 connector.
Turn the ignition switch ON.
Measure the voltage of the wire harness side connector.

Fig 18: Disconnecting C32 Connector

Result

RESULT

Tester Connection	Test Results	Suspected Trouble Areas	Proceed to
C32-9 (EKP) - Body ground	9 V to 14 V	Normal	A
C32-9 (EKP) - Body ground	0 V to 3 V	Power source wire harness of vent valve	B

B: Go to step 32

A: GO TO NEXT STEP

INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION)

Turn the ignition switch OFF.
Disconnect the C32 connector.
Apply the battery voltage to terminals 9 and 8 of the canister pump module.
Touch the canister pump module to confirm the vent valve operation.

Fig 19: Inspecting Canister Pump Module

Result

RESULT

Test Results	Suspected Trouble Areas	Proceed to
Operating	Wire harness between vent valve and ECM	A
Not operating	Vent valve	B

A: Go to step 32

B: Go to step 30

PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FOR CANISTER PUMP MODULE [LEAK DETECTION PUMP])

Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP (ALONE).
Measure the voltage between MPMP terminal of the ECM connector and the body ground when the leak detection pump is turned ON and OFF using the tester.

Fig 20: Identifying VPMP Terminals

Result

RESULT

Tester Connection	Test Results	Suspected Trouble Areas	Proceed to
E2-5 (MPMP) - Body ground	0 V to 3 V when OFF 9 V to 14 V when ON	ECM normal	A
E2-5 (MPMP) - Body ground	9 V to 14 V when OFF 0 V to 3 V when ON	ECM	B

B: Go to step 35

A: GO TO NEXT STEP

CHECK WIRE HARNESS (CANISTER PUMP MODULE - ECM)

Turn the ignition switch OFF.
Disconnect the C32 canister connector.
Turn the ignition switch ON.
Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP (ALONE).
Turn the leak detection pump ON.
Measure the voltage of the wire harness side connectors.

Fig 21: Disconnecting C32 Canister Connector

Result

RESULT

Tester Connection	Test Results	Suspected Trouble Areas	Proceed to
C32-9 (EKP) - Body ground	9 V to 14 V	Normal	A
C32-9 (EKP) - Body ground	0 V to 3 V	Wire harness between ECM and leak detection pump	B

B: Go to step 32

A: GO TO NEXT STEP

CHECK WIRE HARNESS (CANISTER PUMP MODULE - GROUND)

Disconnect the C32 canister connector.
Turn the ignition switch OFF.
Measure the resistance of the wire harness side connectors between terminal 6 of the C32 connector and the body ground.

Fig 22: Disconnecting C32 Canister Connector

Result

RESULT

Tester Connection	Test Results	Suspected Trouble Areas	Proceed to
C32-6 (EKM) - Body ground	Below 1 Ω	Leak detection pump	A
C32-6 (EKM) - Body ground	10 kΩ or higher	Wire harness between leak detection pump and body ground	B

A: Go to step 30

B: Go to step 32

INSPECT INTAKE MANIFOLD (EVAP PURGE PORT)

Turn the ignition switch OFF.
Disconnect the EVAP hose from the intake manifold.
Turn the ignition switch ON.
Use your finger to confirm that the port of the intake manifold has suction.

Result

RESULT

Test Results	Suspected Trouble Areas	Proceed to
Suction applied	EVAP hose between intake manifold and purge VSV	A
No suction	Intake manifold	B

A: Go to step 33

B: Go to step 34

CORRECTLY REINSTALL OR REPLACE FUEL TANK CAP
HINT:
- When reinstalling the fuel tank cap, tighten it until a few click sounds are heard.
- When replacing the fuel tank cap, use a fuel cap that meets OEM specifications, and tighten it until a few click sounds are heard.
NEXT: Go to step 37
REPLACE FUEL TANK CAP
HINT:

When installing the fuel tank cap, tighten it until a few click sounds are heard.

NEXT: Go to step 37
LOCATE EVAP LEAK
1. Disconnect the vent hose here.
  
  Fig 23: Locating Vent Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the pressure gauge to the canister with adapter.
  
  Fig 24: Connecting Pressure Gauge To Canister With Adapter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28 mmHg).
4. Apply soapy water to the piping and connecting parts of the EVAP system.
5. Look for areas where bubbles appear. This indicates the leak point.
6. Repair or replace the leak point.
HINT:

Disconnect the hose between the canister and the fuel tank from the canister. Block the canister side and conduct an inspection. In this way, the fuel tank can be excluded as an area suspected of causing fuel leaks.

NEXT: Go to step 37
REPLACE CANISTER ASSEMBLY
1. Replace the canister assembly.
NOTE: When replacing the canister, check the canister pump module interior and related pipes for water, fuel or other liquids. If liquids are present, check for disconnections and/ or cracks in the following: 1) the pipe from the air inlet port to the canister pump module; 2) the canister filter; and 3) the fuel tank vent hose.

Fig 25: Inspecting Canister Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NEXT: Go to step 37
REPLACE PURGE VSV
1. Disconnect the connector and hoses from the purge VSV.
2. Remove the purge VSV.
3. Install a new purge VSV.
4. Reconnect the connector and hose.
  
  Fig 26: Disconnecting Connector And Hoses From Purge VSV
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NEXT: Go to step 37
REPAIR OR REPLACE HARNESS AND CONNECTOR
NEXT: Go to step 37
REPLACE EVAP HOSE (INTAKE MANIFOLD - PURGE VSV)
NEXT: Go to step 37
INSPECT INTAKE MANIFOLD (EVAP PURGE PORT)
1. Check that the EVAP purge port of the intake manifold is not clogged. If necessary, replace the intake manifold.
NEXT: Go to step 37
REPLACE ECM
1. Replace ECM.
NEXT: Go to step 37
REPAIR OR REPLACE PARTS AND COMPONENTS INDICATED BY OUTPUT DTCS
1. Repair the malfunctioning areas indicated by the DTCs that had been confirmed when the vehicle was brought in.
NEXT: Go to step 37
PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
NOTE:
- In the EVAP SYSTEM CHECK (AUTO OPERATION), the series of 5 EVAP SYSTEM CHECK steps are performed automatically. It takes a maximum of approximately 18 minutes.
- Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut-off valve may be closed, making the leak check of the fuel tank not possible.
- Do not run the engine in this step.
- When the temperature of the fuel is 35 °C (95 °F) or more, a large amount of vapor forms and any check results become inaccurate. When performing an EVAP SYSTEM CHECK, keep the temperature below 35 °C (95 °F).
1. Clear the DTCs (See DTC CHECK/CLEAR ).
2. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION.
3. After the SYSTEM CHECK is completed, check for pending DTCs by entering the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES.
HINT:

If no pending DTC is found, the repair has been successfully completed.

NEXT

COMPLETED