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On-Vehicle Inspection

  1. INSPECT AIR FUEL RATIO COMPENSATION SYSTEM 
    1. Measure the voltage between the terminals of the hybrid vehicle control ECU connectors.

      Standard voltage 

      VOLTAGE SPECIFICATION

      Tester Connection Condition Specified Condition
      H33 - 22 (A1A+) to H32 - 28 (E2) Ignition switch ON 3.3 V
      H33 - 30 (A1A-) to H32 - 28 (E2) Ignition switch ON 3.0 V
      H33 - 23 (A2A+) to H32 - 28 (E2) Ignition switch ON 3.3 V
      H33 - 31 (A2A-) to H32 - 28 (E2) Ignition switch ON 3.0 V
      NOTE: Connect test leads to the connector's back side. The connectors should not be disconnected from the hybrid vehicle control ECU.

      HINT:

      Voltage of the hybrid vehicle control ECU is kept constant regardless of the voltage of the air fuel ratio sensor.

    2. Connect the intelligent tester to the DLC3.
      Fig 1: Identifying ECU Connector Terminal
      G05276491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Select "DATA LIST". Then select "AFS B1 S1", "AFS B2 S1", "O2S B1 S2" and "O2S B2 S2" to display the monitors.
    4. Set the vehicle to 2WD inspection mode. (See REPAIR INSTRUCTION )
    5. Warm up the air fuel ratio sensor with the engine speed at 2,500 rpm for approximately 2 minutes.
    6. Maintain the engine speed at 2,500 rpm and confirm that the displays of "AFS B1 S1" and "AFS B2 S1" are as shown in the illustration.

      HINT:

      • The illustration may differ slightly from the display on the intelligent tester.
      • Only the intelligent tester displays the waveform of the air fuel ratio sensor.
    7. Confirm that the display of "O2S B1 S2" and "O2S B2 S2" changes between 0 and 1 V with the engine speed at 2,500 rpm.
  2. INSPECT FUEL CUT OFF / RESTART RPM 
    1. Increase the engine speed to at least 2,500 rpm.
    2. Use a sound scope to check for injector operating sounds.
    3. Check that when the throttle lever is released, injector operation sound stops momentarily (at 2,500 rpm) and then resumes (at 1,200 rpm).
      Fig 2: Air Fuel Ratio Graph
      G05200943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard 

      ITEM SPECIFICATION

      Item Specified Condition
      Fuel cut off rpm 1,800 rpm
      Fuel injector restart rpm 1,500 rpm
  3. VISUALLY INSPECT HOSE, CONNECTIONS AND GASKETS 
    1. Check for cracks, leaks or damage.

      HINT:

      Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may causes the engine to run improperly. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run improperly.

    Fig 3: Identifying Hoses, Connections And Gaskets
    G05239290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT EVAP SYSTEM LINE 
    1. Warm up the engine to normal operating temperature and stop the engine.
    2. Install a vacuum gauge (EVAP control system test equipment vacuum gauge) into the EVAP service port on the purge line.
      Fig 4: Attaching Vacuum Gauge Into EVAP Service Port On Purge Line
      G05200945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. When using an intelligent tester: Force the VSV for EVAP to operate.
      1. Connect an intelligent tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Date Link Connector 3 (DLC3).
      2. Start the engine.
      3. Turn the intelligent tester main switch on.
      4. Use the ACTIVE TEST mode on the intelligent tester to operate the VSV for the EVAP.
      Fig 5: Checking DTC With Intelligent Tester
      G05202415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. When not using an intelligent tester: Force the VSV for EVAP to operate.
      1. Disconnect the VSV for EVAP connector.
      2. Connect the positive (+) and negative (-) leads from the battery to the VSV for EVAP terminals.
      3. Start the engine.
      Fig 6: Connecting Positive And Negative Leads From Battery To VSV For EVAP Terminals
      G05200947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Check the vacuum.
      1. Set the vehicle to 2WD inspection mode. (See REPAIR INSTRUCTION )

        Vacuum: 

        Maintain between 0.368 and 19.713 in.Hg (5 to 268 in.Ag) for over 5 seconds. 

        HINT:

        If the vacuum does not change, the hose connecting the VSV and the service port is loose or blocked, or the VSV is malfunctioning.

    6. When using an intelligent tester: Conclude operation of the VSV for EVAP.
      1. Stop the engine.
      2. Disconnect the Intelligent tester from the DLC3.
      Fig 7: Checking EVAP System Line Vacuum
      G05200948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. When not using an intelligent tester: Conclude operation of the VSV for EVAP.
      1. Stop the engine.
      2. Disconnect the positive (+) and negative (-) leads of the battery from the VSV for EVAP terminals.
      3. Connect the VSV for EVAP connector.
    8. Disconnect the vacuum gauge from the EVAP service port on the purge line.
    9. Connect a pressure gauge to the EVAP service port on the purge line.
    10. Check the pressure.
      1. Disconnect the charcoal canister hose.
      2. Pinch the charcoal canister hose with the hose clipper to prevent air from entering into the canister passage.
        Fig 8: Pinching Charcoal Canister Hose With Hose Clipper
        G05200949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Apply pressure (13.5 to 15.5 in.Aq, 0.99 to 1.14 in.Hq) from the EVAP service port.

        Pressure: 

        The gauge should still read over 7.7 to 8.8 in.Aq (0.57 to 0.65 in.Hq) for 2 minutes after the pressure is applied. 

        HINT:

        If you cannot apply pressure, the hose connecting the VSV, charcoal canister and fuel tank has slipped off or the VSV is open.

        Fig 9: Applying Pressure Into EVAP Service Port
        G05200950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Check if the pressure decreases when releasing the hose clipper while applying pressure.

        HINT:

        If the pressure does not decrease when the filler cap is removed, the hose connecting the service port and the fuel tank may be blocked.

    11. Disconnect the pressure gauge from the EVAP service port on the purge line.
    Fig 10: Checking Hose Clipper With Pressure
    G05271640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. CHECK AIR TIGHTNESS IN FUEL TANK AND FILLER PIPE 
    1. Press the lid switch to release the pressure in the fuel tank.
    2. Check that the lid is opened.
    3. Disconnect the vent line hose from the fuel tank.
    4. Connect the pressure gauge to the fuel tank.
    5. Apply pressure to the fuel tank to create an internal pressure of 4 kPa (41 gf/cm2 , 0.58 psi).
    6. Check that the internal pressure of the fuel tank is maintained for 1 minute.
    7. Check the connected portions of each hose and pipe.
    8. Check the installed parts on the fuel tank. If any malfunctions, damage or other problems are found, replace the fuel tank and filler pipe.
    9. Reconnect the vent line hose to the fuel tank.
  6. INSPECT FUEL CUT OFF VALVE AND FILL CHECK VALVE 
    1. Press the lid switch to release the pressure in the fuel tank.
    2. Check that the lid is opened.
      Fig 11: Connecting Pressure Gauge To Fuel Tank
      G05200952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the vent line hose from the fuel tank.
    4. Connect the pressure gauge to the fuel tank.
    5. Fill the fuel tank with fuel.
    6. Apply pressure of 4 kPa (41 gf/cm2 , 0.58 psi) to the vent port of the fuel tank.

      HINT:

      Check the amount of fuel in the fuel tank. When the fuel tank is full, the float valve of the fill check valve is closed and no air can pass through.

    7. Remove the fuel tank cap, and check that the pressure drops.

      If the pressure does not drop, replace the fuel tank assembly.

    8. Reconnect the vent line hose to the fuel tank.
    Fig 12: Identifying Fuel Tank Cap With Pressure Gauge
    G05200953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CHECK AIR INLET LINE 
    1. Disconnect the air inlet line hose from the charcoal canister.
    2. Check that air can flow freely into the air inlet line.

      If air cannot flow freely into the air inlet line, repair or replace it.

    3. Reconnect the air inlet line hose to the charcoal canister.
    Fig 13: Checking Air Flow Into Air Inlet Line
    G05200954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSPECT VAPOR PRESSURE SENSOR ASSEMBLY 
    1. Inspect power source voltage of the vapor pressure sensor.
      1. Turn the ignition switch ON.
      2. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the HV control ECU.

        Voltage: 

        4.5 to 5.5 V 

      3. Turn the ignition switch off.
      Fig 14: Identifying HV Control ECU Connector Terminal (1 Of 2)
      G05276504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Inspect power output of the vapor pressure sensor.
      1. Turn the ignition switch ON.
      2. Press the lid switch to release the pressure in the fuel tank.
      3. Check that the lid is opened.
      4. Remove the fuel tank cap.
      5. Using a voltmeter, measure the voltage between connector terminals PTNK and E2 of the HV control ECU.

        Voltage: 

        2.0 to 2.4 V 

        Fig 15: Identifying HV Control ECU Connector Terminal (2 Of 2)
        G05276505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Reinstall the fuel tank cap.
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