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Home >> Toyota >> 2007 >> Tundra Base, 5.7 V, RWD >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System (3UR-FE) - System Testing, Removal & Installation >> EVAP System >> Inspection Procedure
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Inspection Procedure

NOTE: The intelligent tester or Techstream is required to conduct the following diagnostic troubleshooting procedure.

HINT:

  1. 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 intelligent tester or Techstream to the DLC3.
    5. Turn the ignition switch ON and turn the tester ON.
    6. Enter the following menus:
      1. Intelligent tester - Select: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
      2. Techstream - Select: Powertrain / Engine and ECT / Trouble 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 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: DTC Malfunctioning Area Chart
      G05149915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. PERFORM EVAP SYSTEM CHECK (AUTO OPERATION) 
    NOTE:
    • The EVAP SYS CHECK (AUTOMATIC) or Evaporative System Check (Automatic Mode) consists of 5 steps performed automatically by the intelligent tester or Techstream. It takes a maximum of approximately 18 minutes.
    • Do not perform the EVAP SYS CHECK (Evaporative System Check) when the fuel tank is more than 90% full because the cut-off valve may be closed. If the cutoff valve is closed, the fuel tank leak check is not possible.
    • 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 EVAP SYS CHECK (Evaporative System Check), keep the temperature below 35°C (95°F).
    1. Clear DTCs (see DTC CHECK/CLEAR ).
    2. Enter the following menus:
      1. Intelligent tester - Select: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTOMATIC.
      2. Techstream - Select: Powertrain / Engine and ECT / Utility / Evaporative System Check / Automatic Mode.
    3. After the Evaporative System Check is completed, check for pending DTCs by entering the following menus:
      1. Intelligent tester - Select: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES.
      2. Techstream - Select: Powertrain / Engine and ECT / Trouble Codes / Pending.

      HINT:

      If no pending DTCs are displayed, perform the MONITOR CONFIRMATION (see "Diagnostic Help" menu). After this confirmation, check for pending DTCs. If no DTCs are displayed, the EVAP system is normal.

  3. PERFORM EVAP SYSTEM CHECK (MANUAL OPERATION) 
    Fig 2: EVAP System (Manual Operation) Diagram
    G05149924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • In the EVAP SYS CHECK (MANUAL) or Evaporative System Check (Manual Mode), perform the series of 5 EVAP SYS CHECK (Evaporative System Check) steps manually using the intelligent tester or Techstream.
    • Do not perform the EVAP SYS CHECK (Evaporative System Check) when the fuel tank is more than 90% full because the cut-off valve may be closed. If the cutoff valve is closed, the fuel tank leak check is not possible.
    • 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 EVAP SYS CHECK (Evaporative System Check), keep the temperature below 35°C (95°F).
    1. Clear DTCs (see DTC CHECK/CLEAR ).
    2. Enter the following menus:
      1. Intelligent tester - Select: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / MANUAL.
      2. Techstream - Select: Powertrain / Engine and ECT / Utility / Evaporative System Check / Manual Mode.
  4. PERFORM EVAP SYSTEM CHECK (STEP 1/5) 
    Fig 3: EVAP System Diagram (STEP 1/5)
    G05149925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the EVAP pressure in step 1/5.

      Result 

      EVAP SYSTEM CHECK (STEP 1/5)

      DTCs(1) Test Result Suspected Trouble Area Proceed to
      - Virtually no variation in EVAP pressure Not yet determined A
      P0451 EVAP pressure fluctuates by +/-0.3 kPa-g (+/-2.25 mmHg-g) or more Canister pressure sensor noise B
      (1) These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above.

    B:  Go to step  29

    A: Go to next step 

  5. PERFORM EVAP SYSTEM CHECK (STEP 1/5 TO 2/5) 
    Fig 4: EVAP System Diagram (STEP 1/5 TO 2/5)
    G05149926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the EVAP pressure in steps 1/5 and 2/5.

      Result 

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

      DTCs(1) Test Result Suspected Trouble Area Proceed to
      - Virtually no variation in EVAP pressure during step 1/5. Then decreases to reference pressure Not yet determined A
      P2402 Small difference between EVAP pressures during steps 1/5 and 2/5 Leak detection pump stuck ON B
      (1) These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above.

      HINT:

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

    B:  Go to step  22

    A: Go to next step 

  6. PERFORM EVAP SYSTEM CHECK (STEP 2/5) 
    Fig 5: EVAP System Diagram (STEP 2/5)
    G05149927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    Make a note of the pressures checked in steps (a) and (b) below.

    1. Check the EVAP pressure 4 seconds after the leak detection pump is activated*.

      *: The leak detection pump begins to operate as step 1/5 finishes and step 2/5 starts.

    2. Check the EVAP pressure again when it has stabilized. This pressure is the reference pressure.

      Result 

      EVAP SYSTEM CHECK (STEP 2/5)

      DTCs(1) Test Result Suspected Trouble Area 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 A
      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
      		 B
      P043E EVAP pressure in step (b) below -4.85 kPa-g (-36.4 mmHg-g) Reference orifice clogged C
      P2419 EVAP pressure in step (a) more than -1.057 kPa-g (-7.93 mmHg-g) Vent valve stuck closed D
      (1) These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above.

    B:  Go to step  11

    C:  Go to step  29

    D:  Go to step  20

    A: Go to next step 

  7. PERFORM EVAP SYSTEM CHECK (STEP 2/5 TO 3/5) 
    Fig 6: EVAP System Diagram (Step 2/5 To 3/5)
    G05149928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the EVAP pressure increase in step 3/5.

      Result 

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

      DTCs(1) Test Result Suspected Trouble Area 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 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 output value stuck C
      (1) These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above.

    B:  Go to step  19

    C:  Go to step  29

    A: Go to next step 

  8. PERFORM EVAP SYSTEM CHECK (STEP 3/5) 
    Fig 7: EVAP System Diagram (Step 3/5)
    G05149929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Wait until the EVAP pressure change is less than 0.1 kPa-g (0.75 mmHg-g) 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 15 minutes.

  9. PERFORM EVAP SYSTEM CHECK (STEP 4/5) 
    Fig 8: EVAP System Diagram (Step 4/5)
    G05149930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the EVAP pressure in step 4/5.

      Result 

      EVAP SYSTEM CHECK (STEP 4/5)

      DTCs(1) Test Result Suspected Trouble Area 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 A
      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 purge line between purge VSV and intake manifold B
      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 C
      (1) These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above.

    B:  Go to step  15

    C:  Go to step  12

    A: Go to next step 

  10. PERFORM EVAP SYSTEM CHECK (STEP 5/5) 
    Fig 9: EVAP System Diagram (Step 5/5)
    G05149931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the EVAP pressure in step 5/5.
    2. Compare the EVAP pressure in step 3/5 and the second reference pressure (step 5/5).

      Result 

      EVAP SYSTEM CHECK (STEP 5/5)

      DTCs(1) Test Result Suspected Trouble Area Proceed to
      - EVAP pressure (step 3/5) lower than second reference pressure (step 5/5) Not yet determined (no leakage from EVAP system) A
      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
      		 B
      P0456 EVAP pressure (step 3/5) higher than second reference pressure (step 5/5) EVAP small leak B
      (1) These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above.

    A:  Go to step  35

    B:  Go to step  12

  11. PERFORM EVAP SYSTEM CHECK (STEP 3/5) 
    Fig 10: EVAP System Diagram (Step 3/5)
    G05149932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the EVAP pressure in step 3/5.

      Result 

      EVAP SYSTEM CHECK (STEP 3/5)

      DTCs(1) Test Result Suspected Trouble Area Proceed to
      P043F EVAP pressure less than [reference pressure] measured at 2/5 Reference orifice high-flow A
      P2401 EVAP pressure almost same as [reference pressure] measured at 2/5 Leak detection pump stuck OFF B
      (1) These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "CONFIRM DTC" procedures above.

      HINT:

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

    A:  Go to step  29

    B:  Go to step  22

  12. PERFORM ACTIVE TEST USING INTELLIGENT TESTER OR TECHSTREAM (PURGE VSV) 
    1. Enter the following menus:
      1. Intelligent tester - Select: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV (ALONE).
      2. Techstream - Select: Powertrain / Engine and ECT / Active Test / Activate the VSV for EVAP Control.
    2. Disconnect the hose (connected to the canister) from the purge VSV.
    3. Start the engine.
    4. Using the tester, turn off the purge VSV (EVAP VSV (ALONE), Activate the VSV for EVAP Control: OFF).
    5. Use your finger to confirm that the purge VSV has no suction.
    6. Using the tester, turn on the purge VSV (EVAP VSV (ALONE), Activate the VSV for EVAP Control: ON).
    7. Use your finger to confirm that the purge VSV has suction.
      Fig 11: Identifying Purge VSV
      G05149933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result 

      PURGE VSV

      Test Result Suspected Trouble Area 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 purge line between purge VSV and intake manifold
      		 C

    B:  Go to step  14

    C:  Go to step  15

    A: Go to next step 

  13. CHECK FUEL TANK CAP ASSEMBLY 
    1. Check that the fuel tank cap is correctly installed and confirm the fuel tank cap meets OEM specifications.
    2. Tighten the fuel tank cap until a few click sounds are heard.

      HINT:

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

      1. Remove the fuel tank cap and install it onto a fuel tank cap adapter.
      2. 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.
      3. Seal the adapter and wait for 2 minutes.
      4. Check the pressure. If the pressure is 2 kPa (15 mmHg) or more, the fuel tank cap is normal.

        Result 

        FUEL TANK CAP ASSEMBLY

        Test Result Suspected Trouble Area 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
        Defective fuel tank cap - B
        No fuel tank cap - C

    A:  Go to step  28

    B:  Go to step  26

    C:  Go to step  27

  14. INSPECT PURGE VSV 
    1. Turn the ignition switch OFF.
    2. Disconnect the D29 purge VSV connector.
    3. Disconnect the hose (connected to the canister) from the purge VSV.
    4. Start the engine.
    5. Use your finger to confirm that the purge VSV has no suction.
      Fig 12: Identifying Purge VSV
      G05149934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result 

      PURGE VSV

      Test Result Suspected Trouble Area Proceed to
      No suction ECM A
      Suction applied Purge VSV B

    A:  Go to step  34

    B:  Go to step  30

  15. CHECK PURGE LINE (PURGE VSV - INTAKE MANIFOLD) 
    1. Disconnect the hose (connected to the intake manifold) from the purge VSV.
    2. Start the engine.
    3. Use your finger to confirm that the hose has suction.
      Fig 13: Checking Purge Line (Purge VSV - Intake Manifold)
      G05149935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result 

      PURGE LINE (PURGE VSV - INTAKE MANIFOLD)

      Test Result Suspected Trouble Area Proceed to
      Suction applied Purge line between purge VSV and intake manifold normal A
      No suction
      • Intake manifold port
      • Purge line between purge VSV and intake manifold
      		 B

    B:  Go to step  25

    A: Go to next step 

  16. INSPECT PURGE VSV 
    1. Remove the purge VSV (see REMOVAL ).
    2. Apply the battery voltage to the terminals of the purge VSV.
    3. Using an air gun, confirm that air flows from port A to port B.
      Fig 14: Inspecting Purge VSV
      G05149936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result 

      PURGE VSV

      Test Result Suspected Trouble Area Proceed to
      Air flows - A
      No air flow Purge VSV B

    B:  Go to step  30

    A: Go to next step 

  17. CHECK HARNESS AND CONNECTOR (POWER SOURCE OF PURGE VSV) 
    1. Disconnect the D29 purge VSV connector.
    2. Turn the ignition switch ON.
    3. Measure the voltage according to the value(s) in the table below.
      Fig 15: Identifying D29 Purge VSV Connector Connector Terminal
      G05149937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result 

      POWER SOURCE OF PURGE VSV

      Tester Connection Switch Condition Specified Condition Suspected Trouble Area Proceed to
      D29-1 - Body ground Ignition switch ON 11 to 14 V Normal A
      Ignition switch ON Other than condition above Wire harness or connectors between purge VSV and battery B

    B:  Go to step  31

    A: Go to next step 

  18. CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM) 
    1. Disconnect the D74 ECM connector and the D29 purge VSV connectors.
    2. Measure the resistance according to the value(s) in the table below.

      Standard resistance 

      PURGE VSV - ECM

      Tester Connection Condition Specified Condition
      D74-63 (PRG) - 029-2 Always Below 1 Ω
      D74-63 (PRG) - Body ground Always 10 kΩ or higher
      D29-1 - Body ground Always 10 kΩ or higher
      Fig 16: Identifying D74 ECM Connector And D29 Purge VSV Connector Terminal
      G05149938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK:  Go to step  34

    NG:  Go to step  31

  19. INSPECT CANISTER PUMP MODULE (POWER SOURCE FOR VENT VALVE) 
    1. Turn the ignition switch OFF.
    2. Disconnect the R1 canister pump module connector.
    3. Turn the ignition switch ON.
    4. Measure the voltage according to the value(s) in the table below.
      Fig 17: Identifying R1 Canister Pump Module Connector Terminal
      G05149939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result 

      CANISTER PUMP MODULE (POWER SOURCE FOR VENT VALVE)

      Tester Connection Switch Condition Specified Condition Suspected Trouble Area Proceed to
      R1-9 (VLVB) -Body ground Ignition switch ON 11 to 14 V
      1. Wire harness between vent valve and ECM
      2. Vent valve
      3. ECM
      		 A
      Ignition switch ON Below 3 V Power source wire harness of vent valve B

    B:  Go to step  31

    A: Go to next step 

  20. INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION) 
    1. Turn the ignition switch OFF.
    2. Disconnect the R1 canister pump module connector.
    3. Apply the battery voltage to 9 (VLVB) and 8 (VGND) terminals of the canister pump module.
    4. Touch the canister pump module to confirm the vent valve operation.
      Fig 18: Inspecting Canister Pump Module
      G05149940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result 

      CANISTER PUMP MODULE (VENT VALVE OPERATION)

      Test Result Suspected Trouble Area Proceed to
      Operating
      1. Wire harness between vent valve and ECM
      2. ECM
      		 A
      Not operating Vent valve B

    B:  Go to step  29

    A: Go to next step 

  21. CHECK HARNESS AND CONNECTOR (ECM - CANISTER PUMP MODULE) 
    1. Disconnect the A24 ECM connector.
    2. Disconnect the R1 canister pump module connector.
      Fig 19: Identifying A24 ECM Connector And R1 Canister Pump Module Connector
      G05149941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Measure the resistance according to the value(s) in the table below.

      Result 

      ECM - CANISTER PUMP MODULE

      Tester Connection Condition Specified Condition Suspected Trouble Area Proceed to
      A24-30 (VPMP) - R1-8 (VGND) Always Below 1 Ω ECM A
      Always 10 kΩ or higher Wire harness between ECM and canister pump module B

    A:  Go to step  34

    B:  Go to step  31

  22. PERFORM ACTIVE TEST USING INTELLIGENT TESTER OR TECHSTREAM (VACUUM PUMP (ALONE)) 
    1. Turn the ignition switch OFF.
    2. Disconnect the R1 canister pump module connector.
    3. Turn the ignition switch ON.
    4. Enter the following menus:
      1. Intelligent tester - Select: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP.
      2. Techstream - Select: Powertrain / Engine and ECT / Active Test / Activate the Vacuum Pump.
    5. Measure the voltage according to the value(s) in the table below.
      Fig 20: Identifying R1 Canister Pump Module Connector
      G05149942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result 

      VACUUM PUMP (ALONE)

      Tester Connection Condition Specified Condition Suspected Trouble Area Proceed to
      R1-1 (MTRB)-Body ground Leak detection pump is turned ON and OFF using the tester Below 3 V when OFF 9 to 14 V when ON
      1. Wire harness between leak detection pump and body ground
      2. Leak detection pump
      		 A
      Leak detection pump is turned ON and OFF using the tester Below 3 V when OFF and ON
      1. Wire harness between leak detection pump and ECM
      2. ECM
      		 B

    B:  Go to step  24

    A: Go to next step 

  23. CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - BODY GROUND) 
    1. Turn the ignition switch OFF.
    2. Disconnect the R1 canister pump module connector.
    3. Measure the resistance according to the value(s) in the table below.
      Fig 21: Identifying Canister Pump Module And Body Ground
      G05149943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result 

      CANISTER PUMP MODULE - BODY GROUND

      Tester Connection Condition Specified Condition Suspected Trouble Area Proceed to
      R1-6 (MGND)-Body ground Always Below 1 Ω Leak detection pump A
      Always 10 kΩ or higher Wire harness between canister pump module and body ground B

    A:  Go to step  29

    B:  Go to step  31

  24. CHECK HARNESS AND CONNECTOR (ECM - CANISTER PUMP MODULE) 
    1. Turn the ignition switch OFF.
    2. Disconnect the R1 canister pump module connector.
    3. Disconnect the A24 ECM connector.
    4. Measure the resistance according to the value(s) in the table below.
      Fig 22: Identifying R1 Canister Pump Module Connector And A24 ECM Connector Terminal
      G05149944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result 

      ECM - CANISTER PUMP MODULE

      Tester Connection Condition Specified Condition Suspected Trouble Area Proceed to
      A24-49 (MPMP) - R1-1 (MTRB) Always Below 1 Ω ECM A
      Always 10 kΩ or higher Wire harness between ECM and canister pump module B

    A:  Go to step  34

    B:  Go to step  31

  25. INSPECT INTAKE MANIFOLD (EVAP PURGE PORT) 
    1. Stop the engine.
    2. Disconnect the purge line from the intake manifold.
    3. Start the engine.
    4. Use your finger to confirm that the port of the intake manifold has suction.

      Result 

      INTAKE MANIFOLD (EVAP PURGE PORT)

      Test Result Suspected Trouble Area Proceed to
      Suction applied Purge line between intake manifold and purge VSV A
      No suction Intake manifold B
    5. Reconnect the purge line.

    A:  Go to step  32

    B:  Go to step  33

  26. 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 tank cap that meets OEM specifications, and install it until a few click sounds are heard.

    NEXT:  Go to step  36

  27. REPLACE FUEL TANK CAP 

    HINT:

    When replacing the fuel cap, use a fuel cap that meets OEM specifications, and install it until a few click sounds are heard.

    NEXT:  Go to step  36

  28. LOCATE EVAP LEAK PART 
    Fig 23: Identifying EVAP Leak Part
    G05149505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the vent hose.
    2. Connect an EVAP tester 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

  29. REPLACE CANISTER ASSEMBLY 
    1. Replace the canister assembly (see REMOVAL ).
      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 port to the canister pump module; 2) the canister filter; and 3) the fuel tank vent hose.
      Fig 24: Identifying Canister Assembly
      G05149833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NEXT:  Go to step  36

  30. REPLACE PURGE VSV 
    1. Replace the purge VSV (see REMOVAL ).

    NEXT:  Go to step  36

  31. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    NEXT:  Go to step  36

  32. REPLACE PURGE LINE (INTAKE MANIFOLD - PURGE VSV) 

    NEXT:  Go to step  36

  33. 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

  34. REPLACE ECM 
    1. Replace the ECM (see REMOVAL  ).

    NEXT:  Go to step  36

  35. 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.
  36. PERFORM EVAP SYSTEM CHECK (AUTO OPERATION) 
    NOTE:
    • The EVAP SYS CHECK (AUTOMATIC) or Evaporative System Check (Automatic Mode) consists of 5 steps performed automatically by the intelligent tester or Techstream. It takes a maximum of approximately 18 minutes.
    • Do not perform the EVAP SYS CHECK (Evaporative System Check) when the fuel tank is more than 90% full because the cut-off valve may be closed. If the cutoff valve is closed, the fuel tank leak check is 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 SYS CHECK (Evaporative System Check), keep the temperature below 35°C (95°F).
    1. Clear DTCs (see DTC CHECK/CLEAR ).
    2. Enter the following menus:
      1. Intelligent tester - Select: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTOMATIC.
      2. Techstream - Select: Powertrain / Engine and ECT / Utility / Evaporative System Check / Automatic Mode.
    3. After the Evaporative System Check is completed, check for pending DTCs by entering the following menus:
      1. Intelligent tester - Select: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES.
      2. Techstream - Select: Powertrain / Engine and ECT / Trouble Codes / Pending.

      HINT:

      If no pending DTCs are found, the repair has been successfully completed.

    NEXT: COMPLETED 

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