Inspection Procedure

NOTE: Techstream is required to conduct the following diagnostic troubleshooting procedure.

HINT:

Using Techstream monitor results enables the EVAP (Evaporative Emission) system to be confirmed.
Read freeze frame data using Techstream. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air-fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction (See FREEZE FRAME DATA ).

CONFIRM DTC
1. Turn the engine switch off and wait for 10 seconds.
2. Turn the engine switch on (IG).
3. Turn the engine switch off and wait for 10 seconds.
4. Connect Techstream to the DLC3.
5. Turn the engine switch on (IG) and turn the tester ON.
6. Select the following menu items: Powertrain / Engine / Trouble Code.
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 reference pressure difference between the first and second checks is greater than the specification, all the DTCs relating to the reference pressure (P043E, P043F, P2401, P2402 and P2419) are stored.
  
  Fig 1: EVAP System DTCs Chart
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
NOTE:
- The Evaporative System Check (Automatic Mode) consists of 5 steps performed automatically by Techstream. It takes a maximum of approximately 18 minutes.
- Do not perform the Evaporative System Check when the fuel tank is more than 90% full because the cut-off valve may be closed, making the fuel tank leak check unavailable.
- Do not run the engine during this operation.
- 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 Evaporative System Check, keep the temperature below 35°C (95°F).
1. Clear the DTCs (See DTC CHECK/CLEAR ).
2. On the tester, select the following menu items: Powertrain / Engine / Utility / Evaporative System Check / Automatic Mode.
3. After the Evaporative System Check is completed, check for pending DTCs by selecting the following menu items: Powertrain / Engine / Trouble Code / Pending.
  HINT:
  
  If no pending DTCs are displayed, perform the MONITOR CONFIRMATION (see the Diagnostic Help Menu).
  
  After this confirmation, check for pending DTCs. If no DTCs are displayed, the EVAP system is normal.
PERFORM EVAP SYSTEM CHECK (MANUAL OPERATION)

Fig 2: EVAP System Check Chart - Manual Operation
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- In the Evaporative System Check (Manual Mode), perform the series of 5 Evaporative System Check steps manually using Techstream.
- Do not perform the Evaporative System Check when the fuel tank is more than 90% full because the cut-off valve may be closed, making the fuel tank leak check unavailable.
- Do not run the engine during this operation.
- 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 Evaporative System Check, keep the temperature below 35°C (95°F).
1. Clear the DTCs (See DTC CHECK/CLEAR ).
2. Select the following menu items: Powertrain / Engine / Utility / Evaporative System Check / Manual Mode.

PERFORM EVAP SYSTEM CHECK (STEP 1/5)

Check the EVAP pressure in step 1/5.

Fig 3: EVAP System Check Chart - Step 1/5

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT CHART

DTCs⁽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-g (2.25 mmHg-g) or more

Canister pressure sensor noise

⁽¹⁾	The DTCs relating to the EVAP system displayed on Techstream when checking.

B: Go to step 29

A: Go to next step.

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

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

Fig 4: EVAP System Check Chart - Step 1/5 And 2/5

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT CHART

DTCs⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

Virtually no variation in EVAP pressure during step 1/5. Then EVAP pressure decreases to reference pressure.

Not yet determined

P2402

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

Leak detection pump stuck ON

⁽¹⁾	The DTCs relating to the EVAP system displayed on Techstream when checking.

HINT:

The first reference pressure is the value determined in step 2/5.

B: Go to step 22

A: Go to next step.

PERFORM EVAP SYSTEM CHECK (STEP 2/5)

HINT:

Make a note of the pressures checked in steps "A" and "B" below.

Fig 5: EVAP System Check Chart - Step 2/5

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure 4 seconds after the leak detection pump is activated* (Step "A").
*: The leak detection pump begins to operate as step 1/5 finishes and step 2/5 starts.

Check the EVAP pressure again when it has stabilized. This pressure is the reference pressure (Step "B").

Result

RESULT CHART

DTCs⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

EVAP pressure in step (b) between -4.85 kPa-g and -1.057 kPa-g (-36.4 mmHg-g and -7.93 mmHg-g)

Not yet determined

P043F and P2401

EVAP pressure in step (b) -1.057 kPa-g (-7.93 mmHg-g) or more

Reference orifice high-flow
Leak detection pump stuck OFF

P043E

EVAP pressure in step (b) below -4.85 kPa-g (-36.4 mmHg-g)

Reference orifice clogged

P2419

EVAP pressure in step (a) more than -1.057 kPa-g (-7.93 mmHg-g)

Vent valve stuck closed

⁽¹⁾	The DTCs relating to the EVAP system displayed on Techstream when checking.

B: Go to step 11

C: Go to step 29

D: Go to step 20

A: Go to next step.

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

Check the EVAP pressure increase in step 3/5.

Fig 6: EVAP System Check Chart - Step 2/5 To 3/5

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT CHART

DTCs⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

EVAP pressure increases by 0.3 kPa-g (2.25 mmHg-g) 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 malfunction fixed

⁽¹⁾	The DTCs relating to the EVAP system displayed on Techstream when checking.

B: Go to step 19

C: Go to step 29

A: Go to next step.

PERFORM EVAP SYSTEM CHECK (STEP 3/5)
1. Wait until the EVAP pressure change is less than 0.1 kPa-g (0.75 mmHg-g) for 30 seconds.
  
  Fig 7: EVAP System Check Chart - Step 3/5
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 15 minutes.

PERFORM EVAP SYSTEM CHECK (STEP 4/5)

Check the EVAP pressure in step 4/5.

Fig 8: EVAP System Check Chart - Step 4/5

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT CHART

DTCs⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

EVAP pressure increases by 0.3 kPa-g (2.25 mmHg-g) 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-g (2.25 mmHg-g) 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-g (2.25 mmHg-g) for 10 seconds, after proceeding from step 3/5 to step 4/5

Purge VSV stuck closed

⁽¹⁾	The DTCs relating to the EVAP system displayed on Techstream when checking.

B: Go to step 15

C: Go to step 12

A: Go to next step.

PERFORM EVAP SYSTEM CHECK (STEP 5/5)

Check the EVAP pressure in step 5/5.

Fig 9: EVAP System Check Chart - Step 5/5
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Compare the EVAP pressure in step 3/5 and the second reference pressure (step 5/5).

Result

RESULT CHART

DTCs⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

EVAP pressure (step 3/5) lower than second reference pressure (step 5/5)

Not yet determined (no leakage from EVAP system)

P0441 and P0455

EVAP pressure (step 3/5) higher than [second reference pressure (step 5/5) x 0.2]

Purge VSV stuck open
EVAP gross leak

P0456

EVAP pressure (step 3/5) higher than second reference pressure (step 5/5)

EVAP small leak

⁽¹⁾	The DTCs relating to the EVAP system displayed on Techstream when checking.

A: Go to step 35

B: Go to step 12

PERFORM EVAP SYSTEM CHECK (STEP 3/5)

Check the EVAP pressure in step 3/5.

Fig 10: EVAP System Check Chart - Step 3/5

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT CHART

DTCs⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

P043F

EVAP pressure less than reference pressure measured at 2/5

Reference orifice high-flow

P2401

EVAP pressure almost same as reference pressure measured at 2/5

Leak detection pump stuck OFF

⁽¹⁾	The DTCs relating to the EVAP system displayed on Techstream when checking.

HINT:

The first reference pressure is the value determined in step 2/5.

A: Go to step 29

B: Go to step 22

PERFORM ACTIVE TEST USING TECHSTREAM (PURGE VSV)

On Techstream, select the following menu items: Powertrain / Engine / Active Test / Activate the VSV for EVAP Control.
Disconnect the hose (connected to the canister) from the purge VSV.
Start the engine.
Using the tester, turn off the purge VSV (EVAP VSV: OFF).
Use your finger to confirm that the purge VSV has no suction.
Using the tester, turn on the purge VSV (EVAP VSV: ON).

Use your finger to confirm that the purge VSV has suction.

Fig 11: Identifying Purge VSV Hose

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT CHART

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 Problems with EVAP hose between purge VSV and intake manifold	C

Reconnect the hose.

B: Go to step 14

C: Go to step 15

A: Go to next step.

CHECK FUEL CAP ASSEMBLY

Check that the fuel cap is correctly installed and confirm the fuel cap meets OEM specifications.

Tighten the fuel cap until a click sounds are heard.

HINT:

If an EVAP tester is available, check the fuel cap using the tester.

Remove the fuel cap and install it onto a fuel cap adapter.
Connect an EVAP tester pump hose to the adapter, and pressurize the cap to 3.2 to 3.7 kPa (24 to 28 mmHg) using an EVAP tester pump.
Seal the adapter and wait for 2 minutes.

Check the pressure. If the pressure is 2 kPa (15 mmHg) or more, the fuel cap is normal.

Result

RESULT CHART

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

Reinstall the fuel cap.

A: Go to step 28

B: Go to step 26

C: Go to step 27

INSPECT DUTY VACUUM SWITCHING VALVE (PURGE VSV)

Turn the engine switch off.
Disconnect the B42 purge VSV connector.
Disconnect the hose (connected to the canister) from the purge VSV.
Start the engine.

Use your finger to confirm that the purge VSV has no suction.

Fig 12: Identifying Purge VSV Hose

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT CHART

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

Reconnect the purge VSV connector.
Reconnect the hose.

A: Go to step 34

B: Go to step 30

CHECK EVAP HOSE (PURGE VSV - AIR SURGE TANK)

Disconnect the hose (connected to the air surge tank) from the purge VSV.
Start the engine.

Use your finger to confirm that the hose has suction.

Fig 13: Identifying Purge VSV Hose

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT CHART

Test Results	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

Reconnect the hose.

B: Go to step 25

A: Go to next step.

INSPECT DUTY VACUUM SWITCHING VALVE (PURGE VSV)

Remove the purge VSV.
Apply the 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: Applying Battery Voltage To Terminals Of Purge VSV

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT CHART

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

Install the purge VSV.

B: Go to step 30

A: Go to next step.

CHECK HARNESS AND CONNECTOR (POWER SOURCE OF PURGE VSV)

Disconnect the B42 purge VSV connector.
Turn the engine switch on (IG).

Measure the voltage between terminal 2 of the purge VSV connector and body ground.

Fig 15: Identifying Terminals Of B42 Purge VSV Connector

Result

RESULT CHART

Test Results	Suspected Trouble Areas	Proceed to
9 to 14 V	Normal	A
Other than result above	Wire harness or connectors between purge VSV and ECM	B

Reconnect the purge VSV connector.

B: Go to step 31

A: Go to next step.

CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM)

Disconnect the B12 ECM connector and the B42 purge VSV connector.

Measure the resistance.

Standard Resistance

TESTER CONNECTION SPECIFIED CONDITION CHART

Tester Connection	Specified Condition
B12-108 (PRG) - B42-2 (Purge VSV)	Below 1 Ω
B12-108 (PRG) - Body ground	10 kΩ or higher
B42-2 (Purge VSV) - Body ground	10 kΩ or higher

Fig 16: Identifying Terminals Of B12 ECM Connector And B42 Purge VSV Connectors

Reconnect the purge VSV connector.
Reconnect the ECM connector.

OK: Go to step 34

NG: Go to step 31

INSPECT CANISTER PUMP MODULE (POWER SOURCE FOR VENT VALVE)

Turn the engine switch off.
Disconnect the L2 canister pump module connector.
Turn the engine switch on (IG).

Measure the voltage between the VLVB terminal of the canister pump module connector and body ground.

Fig 17: Identifying Terminals Of L2 Canister Pump Module Connector

Result

RESULT CHART

Test Results	Suspected Trouble Areas	Proceed to
9 to 14 V	Wire harness between vent valve and ECM Vent valve ECM	A
Below 3 V	Power source wire harness of vent valve	B

Reconnect the canister pump module connector.

B: Go to step 31

A: Go to next step.

INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION)

Turn the engine switch off.
Disconnect the L2 canister pump module connector.
Apply battery voltage to the VLVB and VGND terminals of the canister pump module.

Touch the canister pump module to confirm the vent valve operation.

Fig 18: Identifying L2 Canister Pump Module Connector

Result

RESULT CHART

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

Reconnect the canister connector.

B: Go to step 29

A: Go to next step.

CHECK HARNESS AND CONNECTOR (ECM - CANISTER PUMP MODULE)

Disconnect the A10 ECM connector.
Disconnect the L2 canister pump module connector.

Measure the resistance between the VPMP terminal of the ECM connector and the VGND terminal of the canister pump module connector.

Fig 19: Identifying Terminals Of L2 Canister Pump Module And A10 ECM Connectors

Result

RESULT CHART

Test Results	Suspected Trouble Areas	Proceed to
Below 1 Ω	ECM	A
10 kΩ or higher	Wire harness between ECM and canister pump module	B

Reconnect the ECM connector.
Reconnect the canister pump module connector.

A: Go to step 34

B: Go to step 31

PERFORM ACTIVE TEST USING TECHSTREAM (VACUUM PUMP (ALONE))

Turn the engine switch off.
Disconnect the L2 canister pump module connector.
Turn the engine switch on (IG).
On Techstream, select the following menu items: Powertrain / Engine / Active Test / Activate the Vacuum Pump.

Measure the voltage between the MTRB terminal of the canister pump module connector and body ground when the leak detection pump is turned ON and OFF using the tester.

Fig 20: Identifying Terminals Of L2 Canister Pump Module Connector

Result

RESULT CHART

Test Results	Suspected Trouble Areas	Proceed to
Below 3 V when OFF 9 to 14 V when ON	Wire harness between leak detection pump and body ground Leak detection pump	A
Below 3 V when OFF and ON	Wire harness between leak detection pump and ECM ECM	B

B: Go to step 24

A: Go to next step.

CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - BODY GROUND)

Turn the engine switch off.
Disconnect the L2 canister pump module connector.

Measure the resistance between the MGND terminal of the canister pump module connector and body ground.

Fig 21: Identifying Terminals Of L2 Canister Pump Module Connector

Result

RESULT CHART

Test Results	Suspected Trouble Areas	Proceed to
Below 1 Ω	Leak detection pump	A
10 kΩ or higher	Wire harness between canister pump module and body ground	B

Reconnect the canister pump module connector.

A: Go to step 29

B: Go to step 31

CHECK HARNESS AND CONNECTOR (ECM - CANISTER PUMP MODULE)

Turn the engine switch off.
Disconnect the L2 canister pump module connector.
Disconnect the A10 ECM connector.

Measure the resistance between the MPMP terminal of the ECM connector and the MTRB terminal of the canister pump module connector.

Fig 22: Identifying Terminals Of L2 Canister Pump Module And A10 ECM Connector

Result

RESULT CHART

Test Results	Suspected Trouble Areas	Proceed to
Below 1 Ω	ECM	A
10 kΩ or higher	Wire harness between ECM and canister pump module	B

Reconnect the canister pump module connector.
Reconnect the ECM connector.

A: Go to step 34

B: Go to step 31

INSPECT INTAKE MANIFOLD (EVAP PURGE PORT)

Stop the engine.
Disconnect the EVAP hose from the intake manifold.
Start the engine.

Use your finger to confirm that the port of the intake manifold has suction.

Result

RESULT CHART

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

Reconnect the EVAP hose.

A: Go to step 32

B: Go to step 33

CORRECTLY REINSTALL OR REPLACE FUEL CAP
HINT:
- When reinstalling the fuel cap, tighten it until a few click sounds are heard.
- When replacing the fuel cap, use a fuel cap that meets OEM specifications, and install it until a click sounds are heard.
NEXT: Go to step 36
REPLACE FUEL CAP
HINT:

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

NEXT: Go to step 36
LOCATE EVAP LEAK PART

Fig 23: Identifying EVAP Pressure Tester Tool And Canister Pump Module
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Disconnect the vent hose.
2. Connect the EVAP pressure tester tool to the canister pump module with the adapter.
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 36
REPLACE CHARCOAL CANISTER ASSEMBLY
1. Replace the canister assembly (See REMOVAL ).
  
  Fig 24: Identifying Canister Assembly Components
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: When replacing the canister, check the canister pump module interior and related pipes for water, fuel and other liquids. If liquids are present, check for disconnections and/or cracks in the following: 1) the pipe from the air inlet pipe to the canister pump module; 2) the canister filter; and 3) the fuel tank vent hose.
NEXT: Go to step 36
REPLACE DUTY VACUUM SWITCHING VALVE (PURGE VSV)
1. Disconnect the connector and the hoses from the purge VSV.
2. Remove the purge VSV (See REMOVAL ).
3. Install a new purge VSV (See INSTALLATION ).
4. Reconnect the connector and hoses.
NEXT: Go to step 36

Fig 25: Locating Purge VSV Connector And Hoses
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPAIR OR REPLACE HARNESS OR CONNECTOR
NEXT: Go to step 36
REPLACE EVAP HOSE (INTAKE MANIFOLD - PURGE VSV)
NEXT: Go to step 36
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 36
: REPLACE ECM
1. Replace the ECM (See REMOVAL ).
NEXT: Go to step 36
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 36
PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
NOTE:
- The Evaporative System Check (Automatic Mode) consists of 5 steps performed automatically by Techstream. It takes a maximum of approximately 18 minutes.
- Do not perform the Evaporative System Check when the fuel tank is more than 90% full because the cut-off valve may be closed, making the fuel tank leak check unavailable.
- 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 Evaporative System Check, keep the temperature below 35°C (95°F).
1. Clear the DTCs (See DTC CHECK/CLEAR ).
2. On Techstream, select the following menu items: Powertrain / Engine / Utility / Evaporative System Check / Automatic Mode.
3. After the Evaporative System Check is completed, check for pending DTCs by selecting the following menu items: Powertrain / Engine / Trouble Code / Pending.
  HINT:
  
  If no pending DTCs are found, the repair has been successfully completed.
NEXT: COMPLETED