Inspection Procedure
HINT:
- Using the intelligent tester monitor results enable the EVAP system to be confirmed.
- Read freeze frame data using the intelligent 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
- Turn the ignition switch OFF and wait for 10 seconds.
- Turn the ignition switch ON.
- Turn the ignition switch OFF and wait for 10 seconds.
- Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3.
- Turn the ignition switch ON.
- Enter the following menus: DIAGNOSIS / ENHANCED OBD II/DTC INFO / CURRENT CODES.
- Confirm DTCs and freeze frame data.
If any EVAP system DTCs are set, the malfunctioning area can be determined using Fig 1 .
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.
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).
- Clear the DTCs (see DTC CHECK/CLEAR ).
- Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION.
- After the EVAP 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 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)
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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).
- Clear the DTCs (see DTC CHECK/CLEAR ).
- Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / MANUAL OPERATION.
NEXT
- PERFORM EVAP SYSTEM CHECK (STEP 1/5)
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- Check the EVAP pressure in step 1/5.
Result
RESULTDTC No. (1) Test Results Suspected Trouble Areas Proceed to - Virtually no variation in EVAP pressure Not yet determined A P0451 EVAP pressure fluctuates by +- 0.3 kPa (2.25 mmHg) or more Canister pressure sensor noising B (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
- Check the EVAP pressure in step 1/5.
- PERFORM EVAP SYSTEM CHECK (STEP 1/5 TO 2/5)
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- Check the EVAP pressure in step 1/5 and 2/5.
Result
RESULTDTC 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 A P2402 Small difference between EVAP pressures during steps 1/5 and 2/5 Leak detection pump stuck ON B (1) The DTCs related to the EVAP system are displayed on the intelligent tester when checking. HINT:
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
- Check the EVAP pressure in step 1/5 and 2/5.
- PERFORM EVAP SYSTEM CHECK (STEP 2/5)
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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
RESULTDTC 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 A 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
B P043E EVAP pressure in step (b) below -4.85 kPa (-36.38 mmHg) Reference orifice clogged C P2419 EVAP pressure in step (a) more than -1.06 kPa (-7.95 mmHg) Vent valve stuck closed D (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
- Check the EVAP pressure 4 seconds after the leak detection pump is activated*.
- PERFORM EVAP SYSTEM CHECK (STEP 2/5 TO 3/5)
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- Check the EVAP pressure in step 3/5.
Result
RESULTDTC 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 A P2420 No variation in EVAP pressure despite proceeding from step 2/5 to step 3/5 Vent valve stuck open (vent) B P0451 No variation in EVAP pressure during steps 1/5 through 3/5 Canister pressure sensor malfunction (stuck) C (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
- Check the EVAP pressure in step 3/5.
- PERFORM EVAP SYSTEM CHECK (STEP 3/5)
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- Wait until the EVAP pressure change is less than 0.1 kPa (0.75 mmHg) for 30 seconds.
- 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.
NEXT
- PERFORM EVAP SYSTEM CHECK (STEP 4/5)
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- Check the EVAP pressure in step 4/5.
Result
RESULTDTC 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 A 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 B P0441 Variation in EVAP pressure less than 0.3 kPa (2.25 mmHg) for 10 seconds, after proceeding from step 3/5 to step 4/5 Purge VSV stuck closed C (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
- Check the EVAP pressure in step 4/5.
- PERFORM EVAP SYSTEM CHECK (STEP 5/5)
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- 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
RESULTDTC 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 A P0441 and P0455 EVAP pressure (step 3/5) higher than [second 0.02 inch leak criterion (step 5/5) x 0.2] - Purge VSV stuck open
- EVAP gross leak
B P0456 EVAP pressure (step 3/5) higher than second 0.02 inch leak criterion (step 5/5) EVAP small leak C (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)
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- Check the EVAP pressure in step 3/5.
Result
RESULTDTC 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 A P2401 EVAP pressure almost same as [0.02 inch leak criterion] measured at 2/5 Leak detection pump stuck OFF B (1) The DTCs related to the EVAP system are displayed on the intelligent tester when checking. HINT:
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
- Check the EVAP pressure in step 3/5.
- 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.
Result
RESULTTest 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
B: Go to step 14
C: Go to step 15
A: GO TO NEXT STEP
- CHECK FUEL CAP
- Check that the fuel cap is correctly installed.
- Tighten the fuel cap until a few click sounds are heard.
HINT:
If an EVAP tester is available, use the tester to check the fuel cap.
- Tighten the fuel cap until a few click sounds are heard.
- Remove the fuel cap and install it onto the fuel 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 cap is normal.
Result
RESULTTest 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 No fuel cap - C
A: Go to step 29
B: Go to step 27
C: Go to step 28
- Check that the fuel cap is correctly installed.
- 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.
Result
RESULTTest 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 EVAP 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.
Result
RESULTTest 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
B: Go to step 26
A: GO TO NEXT STEP
- INSPECT DUTY 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.
Result
RESULTTest Results 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 HARNESS AND CONNECTOR (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.
Result
RESULTTest Results Suspected Trouble Areas Proceed to Between 11 V and 14 V Normal A 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 HARNESS AND CONNECTOR (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 CONDITIONTester Connection Specified Condition V4-1 - E5-34 (PRG) Below 1 Ω V4-1 or E5-34 (PRG) - Body ground 10 kΩ or higher
OK: Go to step 35
NG: Go to step 32
- 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.
Result
RESULTTest Results Suspected Trouble Areas Proceed to Between 9 V and 14 V when OFF
Below 3 V when ONVent valve A Below 3 V when OFF and ON ECM B
A: Go to step 22
B: 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.
Result
RESULTTest Results Suspected Trouble Areas Proceed to Below 3 V when OFF and ON Power source of vent valve A Between 9 V and 14 V when OFF
Below 3 V when ONVent valve B 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 L5 canister connector.
- Turn the ignition switch ON.
- Measure the voltage between terminal 9 of the canister connector and the body ground.
Result
RESULTTest Results Suspected Trouble Areas Proceed to Between 9 V and 14 V Normal A Between 0 V and 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 L5 canister 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.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Result
RESULTTest 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.
Result
RESULTTest Results Suspected Trouble Areas Proceed to Between 0 V and 3 V when OFF
Between 9 V and 14 V when ONECM normal A Between 9 V and 14 V when OFF
Between 0 V and 3 V when ONECM B
B: Go to step 35
A: GO TO NEXT STEP
- CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - ECM)
- Turn the ignition switch OFF.
- Disconnect the L5 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 between terminal 1 of the canister connector and the body ground.
Result
RESULTTest Results Suspected Trouble Areas Proceed to Between 9 V and 14 V Normal A Between 0 V and 3 V Wire harness between ECM and leak detection pump B
B: Go to step 32
A: GO TO NEXT STEP
- CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - GROUND)
- Disconnect the L5 canister connector.
- Turn the ignition switch OFF.
- Measure the resistance of the wire harness side connectors between terminal 6 of the canister connector and the body ground.
Result
RESULTTest Results Suspected Trouble Areas Proceed to Below 1 Ω Leak detection pump A 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
RESULTTest 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 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 tighten it until a few click sounds are heard.
NEXT: Go to step 37
- REPLACE FUEL CAP
HINT:
When installing the fuel cap, tighten it until a few click sounds are heard.
NEXT: Go to step 37
- REPAIR EVAP LEAKING PART
- Reinstall the fuel cap.
- Using SST, pinch the atmospheric side hose of the canister pump module to close the canister passage to air.
- Connect a pressure gauge (SST) to the service port (green cap near the air cleaner box).
- Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28 mmHg).
- Apply soapy water to the piping and connecting parts of the EVAP system. Look for areas where bubbles appear. This indicates leaking parts.
- Repair or replace leaking part.
HINT:
Disconnect the hose between the canister and the fuel tank from the canister. Close the canister hose connected to the fuel tank, 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
NEXT: Go to step 37
- REPLACE DUTY PURGE VSV
- Disconnect the connector and hoses from the purge VSV.
- Remove the purge VSV.
- Install a new purge VSV.
- Reconnect the connector and hose.
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)
- 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
- Replace ECM (see REMOVAL ).
NEXT: Go to step 37
- REPAIR OR REPLACE PARTS AND COMPONENTS INDICATED BY OUTPUT DTCS
- 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).
- Clear the DTCs (see DTC CHECK/CLEAR ).
- Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION.
- 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