On-Vehicle Inspection

WARNING: This page is about a different car, the 2004 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.

VISUALLY INSPECT HOSES, 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 the cylinder head will allow air suction and cause the engine to run improperly.

Fig 1: Visually Inspect Hoses, Connections And Gaskets
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT EVAP SYSTEM LINE
1. Warm up the engine to normal operating temperature.
2. Turn the engine OFF.
3. Connect the vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge line.
  
  Fig 2: Connected Vacuum Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. If you have hand-held tester:
  Turn on the VSV for EVAP using the hand-held tester.
  1. Connect the hand-held tester to the DLC3.
  2. Start the engine.
  3. Push the hand-held tester main switch ON.
  4. Use the ACTIVE TEST mode on the hand-held tester to operate the VSV for EVAP.
  Fig 3: Inspecting VSV For EVAP Using Hand-Held Tester
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. If you have no hand-held tester:
  Turn on the VSV for EVAP using the lead wires.
  1. Disconnect the VSV for EVAP connector.
  2. Connect the positive (+) and negative (-) leads from the battery to the VSV for EVAP terminals.
    
    Fig 4: Connecting Positive (+) And Negative (-) Leads From The Battery To The VSV
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Start the engine.
6. Check the vacuum at idle.
  
  Fig 5: Checking Vacuum At Idle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Vacuum:
  
  Maintain at 0.368 to 19.713 in.Hg (5 to 268 in.Aq) for over 5 seconds
  
  HINT:
  
  If the vacuum does not change, you can conclude that the hose connecting the VSV to the service port has come loose or is blocked, or the VSV is malfunctioning.
7. If you have hand-held tester:
  Return to normal the VSV for EVAP operation.
  1. Stop the engine.
  2. Disconnect the hand-held tester from the DLC3.
8. If you have no hand-held tester:
  Return to normal the VSV for EVAP operation.
  1. Stop the engine.
  2. Disconnect the positive (+) and negative (-) leads from the VSV for EVAP terminals.
  3. Reconnect the VSV for EVAP connector.
9. Disconnect the vacuum gauge from the EVAP service port on the purge line.
10. Connect a pressure gauge to the EVAP service port on the purge line.
  
  Fig 6: Connecting A Pressure Gauge To EVAP Service Port On Purge Line
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. If you have hand-held tester:
  Turn on the VSV for CCV using the hand-held tester.
  1. Connect the hand-held tester to the DLC3.
  2. Turn the ignition switch ON.
  3. Push the hand-held tester main switch ON.
  4. Use the ACTIVE TEST mode on the hand-held tester to operate the VSV for CCV.
  NOTE: Do not start the engine.
  
  HINT:
  
  If the check is not completed within 10 minutes, the forced close If VSV for CCV will be reset.
  
  Fig 7: Connecting Hand-Held Tester To DLC3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. If you have no hand-held tester:
  Turn on the VSV for the CCV using the lead wires.
  1. Disconnect the VSV for CCV connector.
  2. Connect the positive (+) and negative (-) leads from the battery to the VSV for CCV terminals.
13. Check the pressure.
  1. Add the pressure (13.5 to 15.5 in.Aq) from the EVAP service port.
    Pressure:
    
    2 minutes after the pressure is added, the gauge should be over 7.7 to 8.8 in.Aq.
    
    HINT:
    
    If you can not add pressure, you can conclude that the hose connecting the VSV for EVAP canister fuel tank has slipped off or the VSV is open.
    
    Fig 9: Checking Pressure From EVAP Service Port
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Check if the pressure decreases when the fuel tank cap is removed while adding pressure.
    HINT:
    
    If the pressure does not decrease when the fuel tank cap is removed, you can conclude that the hose connecting the service port to the fuel tank is blocked, etc.
14. If you have hand-held tester:
  Turn to normal VSV for CCV operation.
  1. Turn ignition switch OFF.
  2. Disconnect the hand-held tester from the DLC3.
  Fig 10: Disconnecting Hand-Held Tester From DLC3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. If you have no hand-held tester:
  Turn to normal VSV for CCV operation.
  1. Disconnect the positive (+) and negative (-) leads from the VSV for CCV terminals.
  2. Reconnect the VSV for CCV connector.
16. Disconnect the pressure gauge from the EVAP service port on the purge line.
CHECK AIR TIGHTNESS IN FUEL TANK AND FILLER PIPE
1. Disconnect the vent line hose from the charcoal canister.
2. Apply pressure to fuel tank and make the internal pressure of the fuel tank 4 kPa (41 gf/cm² , 0.58 psi).
3. Check that the internal pressure of the fuel tank is remains stable for 1 minute.
4. Check the connected portions of each hose and pipe.
  
  Fig 11: Checking Connected Portions Of Each Hose And Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check the installed parts on the fuel tank.
  If they are OK, replace the fuel tank and filler pipe.
6. Reconnect the vent line hose to the fuel tank.
INSPECT FUEL CUTOFF VALVE AND FILL CHECK VALVE
1. Disconnect the vent line hose from the charcoal canister.
2. Apply 4 kPa (41 gf/cm² , 0.58 psi) to the vent port of the fuel tank.
  HINT:
  
  In the condition that the fuel is full, as the float value of the fill check valve is closed and has no ventilation, it is necessary to check the fuel amount (volume).
3. Remove the fuel tank cap, and check that pressure drops.
  
  Fig 12: Inspecting Fuel Cutoff Valve And Fill Check Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If pressure does not drop, replace the fuel tank assembly.
4. Reconnect the vent line hose to the fuel tank.
CHECK AIR INLET LINE
1. Disconnect the air inlet line hose from the charcoal canister.
2. Check that there is ventilation in the air inlet line.
3. Reconnect the air inlet line hose to the charcoal canister.
Fig 13: Connecting Air Inlet Line
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT VAPOR PRESSURE SENSOR
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 wiring harness side.
    Voltage: 4.5 to 5.5 V
    
    Fig 14: Measuring Voltage Between Connector Terminals VC And E2 Of Wiring Harness Side
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Turn the ignition switch OFF.
2. Inspect power output of the vapor pressure sensor.
  1. Turn the ignition switch ON.
  2. Remove the fuel tank cap.
  3. Using a voltmeter, measure the voltage between connector terminals PTNK and E2 of the wiring harness side.
    Voltage: 3.0 to 3.6 V
  4. Reinstall the fuel tank cap.
  Fig 15: Reinstalling Fuel Tank Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002