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Inspection Procedure

NOTE: A hand-held tester is required to conduct the following diagnostic troubleshooting procedure.

HINT:

  1. CONFIRM DTC 
    1. Turn the ignition switch to OFF and wait for 10 seconds.
    2. Turn the ignition switch to ON.
    3. Turn the ignition switch to OFF and wait for 10 seconds.
    4. Connect a hand-held tester to the DLC3.
    5. Turn the ignition switch to ON and turn the tester ON.
    6. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT 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.

      Fig 1: Malfunctioning Area Chart
      G04676471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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, P2420) will be all stored.
  2. PERFORM EVAP SYSTEM CHECK (AUTO OPERATION) 
    NOTE:
    • In the EVAP SYSTEM CHECK (AUTO OPERATION), the series of 5 EVAP SYSTEM CHECK steps is 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 and making the leak check of the fuel tank 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 the EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F).
    1. Clear DTCs (See DTC CHECK/CLEAR ).
    2. On the hand-held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION.
    3. After the EVAP SYSTEM CHECK is completed, check for pending DTCs by selecting the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES.

    HINT:

    If no pending DTC is displayed, perform the Monitor Confirmation after this repair is completed. After this confirmation, check for pending DTCs. If no DTC is displayed, the EVAP system is normal.

  3. PERFORM EVAP SYSTEM CHECK (MANUAL OPERATION) 
    Fig 2: Performing Evap System Check (Manual Operation)
    G04676472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • In the EVAP SYSTEM CHECK (MANUAL OPERATION), the series of 5 EVAP SYSTEM CHECK steps is 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 and making the leak check of the fuel tank 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 the EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F).
    1. Clear DTCs (See DTC CHECK/CLEAR ).
    2. On the hand-held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / MANUAL OPERATION.
  4. PERFORM EVAP SYSTEM CHECK (STEP 1/5) 
    Fig 3: Performing EVAP System Check (Step 1/5)
    G04676473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the EVAP pressure in step 1/5.

      Result: 

      EVAP SYSTEM CHECK (STEP 1/5)

      DTCs(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 Pressure sensor noising B
      (1) The DTCs relating to the EVAP system displayed on a hand-held tester when checking.

    B: Go to step   30 

    A: Go to next step. 

  5. PERFORM EVAP SYSTEM CHECK (STEP 1/5 TO 2/5) 
    Fig 4: Performing EVAP System Check (Step 1/5 To 2/5)
    G04676474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the EVAP pressure in step 1/5 and 2/5.

      Result: 

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

      DTCs(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 pressure standard(1) Not yet determined A
      P2402 Small difference between EVAP pressures during steps 1/5 and 2/5 Vacuum pump stuck ON B
      (1) The DTCs relating to the EVAP system displayed on a hand-held tester when checking.

      HINT:

      The 0.02 inch leak pressure standard is the value determined in step 2/5.

    B: Go to step   23 

    A: Go to next step. 

  6. PERFORM EVAP SYSTEM CHECK (STEP 2/5) 
    Fig 5: Performing EVAP System Check (Step 2/5)
    G04676475Courtesy 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 vacuum pump is activated*.
    2. Check the EVAP pressure again when it has stabilized. This pressure is the 0.02 inch leak pressure standard.

    *: The vacuum pump begins to operate as step 1/5 is proceeded to step 2/5.

    Result: 

    EVAP SYSTEM CHECK (STEP 2/5)

    DTCs(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
    • 0.02 inch orifice high-flow
    • Vacuum pump stuck OFF
    		 B
    P043E EVAP pressure in step (b) below -4.85 kPa (-36.38 mmHg) 0.02 inch 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 relating to the EVAP system displayed on a hand-held tester when checking.

    B: Go to step   11 

    C: Go to step   30 

    D: Go to step   19 

    A: Go to next step. 

  7. PERFORM EVAP SYSTEM CHECK (STEP 2/5 TO 3/5) 
    Fig 6: Performing EVAP System Check (Step 2/5 To 3/5)
    G04676476Courtesy 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 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 Pressure sensor malfunction stuck C
    (1) The DTCs relating to the EVAP system displayed on a hand-held tester when checking.

    B: Go to step   19 

    C: Go to step   30 

    A: Go to next step. 

  8. PERFORM EVAP SYSTEM CHECK (STEP 3/5) 
    Fig 7: Performing EVAP System Check (Step 3/5)
    G04676477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Wait until the EVAP pressure change is less than 0.1 kPa (0.75 mmHg) 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 12 minutes.

  9. PERFORM EVAP SYSTEM CHECK (STEP 4/5) 
    Fig 8: Performing EVAP System Check (Step 4/5)
    G04676478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the EVAP pressure in step 4/5.
    EVAP SYSTEM CHECK (STEP 4/5)

    DTCs(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 pure VSV and throttle body B
    P0441 Variation in EVAP pressure is 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 relating to the EVAP system displayed on a hand-held tester when checking.

    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: Performing EVAP System Check (Step 5/5)
    G04676479Courtesy 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 0.02 inch leak pressure standard (step 5/5).

    Result: 

    EVAP SYSTEM CHECK (STEP 5/5)

    DTCs(1) Test Results Suspected Trouble Areas Proceed To
    - EVAP pressure (step 3/5) lower than the second 0.02 inch leak pressure standard (step 5/5) Not yet determined (no leakage from EVAP system) A
    P0441 and P0455 EVAP pressure (step 3/5) higher than [second 0.02 inch leak pressure standard (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 pressure standard (step 5/5) EVAP small leak B
    (1) The DTCs relating to the EVAP system displayed on a hand-held tester when checking.

    A: Go to step   36 

    B: Go to step   12 

  11. PERFORM ACTIVE TEST USING HAND-HELD TESTER (STEP 3/5) 
    Fig 10: Performing Active Test Using Hand-Held Tester (Step 3/5)
    G04676480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the EVAP pressure in step 3/5.

    Result: 

    ACTIVE TEST USING HAND-HELD TESTER (STEP 3/5)

    DTCs(1) Test Results Suspected Trouble Areas Proceed To
    - EVAP pressure less than [0.02 inch leak pressure standard x 0.2] 0.02 inch orifice high-flow A
    - EVAP pressure more than [0.02 inch leak pressure standard x 0.2] Vacuum pump stuck OFF B
    HINT:
    (1) The DTCs relating to the EVAP system displayed on a hand-held tester when checking.

    The 0.02 inch leak pressure standard is the value determined in step 2/5.

    A: Go to step   30 

    B: Go to step   23 

  12. PERFORM ACTIVE TEST USING HAND-HELD TESTER (PURGE VSV) 
    1. On the hand-held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II/ ACTIVE TEST / EVAP VSV.
    2. Disconnect the hose (connected to the canister) from the purge VSV.
    3. Start the engine.
    4. On the tester, turn off the purge VSV (EVAP VSV: 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: ON).
    7. Use your finger to confirm that the purge VSV has suction.
      Fig 11: Performing Active Test Using Hand-Held Tester (Purge VSV)
      G04676481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Result: 

    ACTIVE TEST USING HAND-HELD TESTER (PURGE VSV)

    Test Results Suspected Trouble Areas Proceed To
    No suction when purge VSV turned OFF, and suction applied when tuned 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 throttle body
    		 C

    B: Go to step   14 

    C: Go to step   15 

    A: Go to next step. 

  13. CHECK FUEL TANK CAP ASSY 
    1. Check that the fuel tank cap is correctly installed.
    2. Confirm that the fuel tank cap is tightened 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 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.
      5. Reinstall the fuel tank cap.

    Result: 

    FUEL TANK CAP ASSY

    Test Results Suspected Trouble Areas 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
    No fuel tank cap - C

    A: Go to step   29 

    B: Go to step   27 

    C: Go to step   28 

  14. INSPECT VACUUM SWITCHING VALVE ASSY NO. 1 
    1. Turn the ignition switch to OFF.
    2. Disconnect the V2 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: Inspecting Vacuum Switching Valve Assy No. 1
      G04676482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result: 

      VACUUM SWITCHING VALVE ASSY NO. 1

      Test Results Suspected Trouble Areas Proceed To
      No suction ECM A
      Suction applied Purge VSV B
    6. Reconnect the purge VSV connector.

    A: Go to step   34 

    B: Go to step   30 

  15. CHECK EVAP HOSE (PURGE VSV - THROTTLE BODY) 
    1. Disconnect the hose (connected to the throttle body) from the purge VSV.
    2. Start the engine.
    3. Use your finger to confirm that the hose has suction.
      Fig 13: Checking EVAP Hose (Purge VSV - Throttle Body)
      G04676483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result: 

      EVAP HOSE (PURGE VSV - THROTTLE BODY)

      Test results Suspected Trouble Areas Proceed To
      Suction applied EVAP hose between purge VSV and throttle body normal A
      No suction
      • Throttle body
      • EVAP hose between purge VSV and throttle body
      		 B

      B: Go to step   26 

      A: Go to next step. 

  16. INSPECT VACUUM SWITCHING VALVE ASSY NO. 1 (PURGE VSV) 
    1. Remove the purge VSV.
    2. Apply battery voltage to the terminals of the purge VSV.
    3. Blow air into port A and check that air is discharged from the port B.
      Fig 14: Inspecting Vacuum Switching Valve Assy No. 1 (Purge VSV)
      G04676484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result: 

      VACUUM SWITCHING VALVE ASSY NO. 1 (PURGE VSV)

      Test Results Suspected Trouble Areas Proceed To
      Suction applied EVAP hose between purge VSV and throttle body normal A
      No suction
      • Throttle body
      • EVAP hose between purge VSV and throttle body
      		 B

      B: Go to step   31 

      A: Go to next step. 

  17. CHECK WIRE HARNESS AND CONNECTOR (POWER SOURCE OF PURGE VSV) 
    1. Disconnect the V2 purge VSV connector.
    2. Turn the ignition switch to ON.
    3. Measure the voltage between terminal 1 of the purge VSV connector and the body ground.
      Fig 15: Checking Wire Harness And Connector (Power Source Of Purge VSV)
      G04676485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result: 

      POWER SOURCE OF PURGE VSV

      Test 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
    4. Reconnect the purge VSV connector.

    B: Go to step   32 

    A: Go to next step. 

  18. CHECK WIRE HARNESS AND CONNECTOR (PURGE VSV - ECM) 
    1. Disconnect the E5 ECM connector and the V2 purge VSV connector.
    2. Check the resistance.

      Standard: 

      PURGE VSV - ECM

      Tester Connections Specified Conditions
      PRG (E5-34) - VSV (V2-1) Below 1 Ω
      PRG (E5-34) - Body ground 10 kΩ or higher
      VSV (V2-1) - Body ground 10 kΩ or higher
      Fig 16: Checking Wire Harness And Connector (Purge VSV - ECM)
      G04676486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 17: Identifying Purge VSV Connector
      G04676487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Reconnect the ECM connector.
    4. Reconnect the purge VSV connector.

    OK: Go to step   35 

    NG: Go to step   32 

  19. PERFORM ACTIVE TEST USING HAND-HELD TESTER (FOR VENT VALVE) 
    1. Turn the ignition switch to ON.
    2. On the hand-held tester, select the following menu items: DIAGNOSIS/ ENHANCED OBD II/ ACTIVE TEST/ VENT VALVE (ALONE).
    3. 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.
      Fig 18: Performing Active Test Using Hand-Held Tester (For Vent Valve)
      G04676488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result: 

      ACTIVE TEST USING HAND-HELD TESTER (FOR VENT VALVE)

      Test Results Suspected Trouble Areas Proceed To
      Between 9 V and 14 V when OFF
      Below 3 V when ON      		 Vent valve A
      Below 3 V when OFF and ON ECM B

    A: Go to step   22 

    B: Go to step   35 

  20. PERFORM ACTIVE TEST USING HAND-HELD TESTER (FOR VENT VALVE) 
    1. Turn the ignition switch to ON.
    2. On the hand-held tester, select the following menu items: DIAGNOSIS/ ENHANCED OBD II/ ACTIVE TEST/ VENT VALVE (ALONE).
    3. 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.
      Fig 19: Performing Active Test Using Hand-Held Tester (For Vent Valve)
      G04676489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result: 

      ACTIVE TEST USING HAND-HELD TESTER (FOR VENT VALVE)

      Test 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 ON      		 Vent valve B
      Between 9 V and 14 V when OFF and ON ECM C

    B: Go to step   24 

    C: Go to step   35 

    A: Go to next step. 

  21. INSPECT PUMP MODULE (POWER SOURCE FOR VENT VALVE) 
    1. Turn the ignition switch to OFF.
    2. Disconnect the L4 canister connector.
    3. Turn the ignition switch to ON.
    4. Measure the voltage between terminal 9 of the canister connector and the body ground.
      Fig 20: Inspecting Pump Module (Power Source For Vent Valve)
      G04676490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 21: Identifying Canister Connector
      G04676491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result: 

      PUMP MODULE (POWER SOURCE FOR VENT VALVE)

      Test 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
    5. Reconnect the canister connector.

    B: Go to step   32 

    A: Go to next step. 

  22. INSPECT PUMP MODULE (VENT VALVE OPERATION) 
    1. Disconnect the L4 canister connector.
    2. Turn the ignition switch to OFF.
    3. Apply the battery voltage to terminals 9 and 8 of the pump module.
    4. Touch the pump module to confirm the vent valve operation.
      Fig 22: Inspecting Pump Module (Vent Valve Operation)
      G04676492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result: 

      PUMP MODULE (VENT VALVE OPERATION)

      Test Results Suspected Trouble Areas Proceed To
      Operating Wire harness between vent valve and ECM A
      Not operating Vent valve B
    5. Reconnect the casister connector.

    A: Go to step   32 

    B: Go to step   30 

  23. PERFORM ACTIVE TEST USING HAND-HELD TESTER (FOR PUMP MODULE (VACUUM PUMP)) 
    1. On the hand-held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP (ALONE).
    2. Measure the voltage between terminal MPMP of the ECM connector and the body ground when the vacuum pump is turned ON and OFF using the tester.
      Fig 23: Performing Active Test Using Hand-Held Tester (For Pump Module (Vacuum Pump))
      G04676493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result: 

      ACTIVE TEST USING HAND-HELD TESTER (FOR PUMP MODULE (VACUUM PUMP))

      Tests Results Suspected Trouble Areas Proceed To
      Between 0 V and 3 V when OFF
      Between 9 V and 14 V when ON      		 ECM normal A
      Between 9 V and 14 V when OFF
      Between 0 V and 3 V when ON      		 ECM B

    B: Go to step   35 

    A: Go to next step. 

  24. CHECK WIRE HARNESS AND CONNECTOR (PUMP MODULE - ECM) 
    1. Turn the ignition switch to OFF.
    2. Disconnect the L4 canister connector.
    3. Turn the ignition switch to ON.
    4. On the hand- held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP (ALONE).
    5. Turn the vacuum pump ON.
    6. Measure the voltage between terminal 1 of the canister connector and the body ground.
      Fig 24: Checking Wire Harness And Connector (Pump Module - ECM)
      G04676494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 25: Identifying Canister Connector
      G04676495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result: 

      PUMP MODULE - ECM

      Test 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 vacuum pump B
    7. Reconnect the casister connector.

    B: Go to step   32 

    A: Go to next step. 

  25. CHECK WIRE HARNESS AND CONNECTOR (PUMP MODULE - GROUND) 
    1. Disconnect the L4 canister connector.
    2. Turn the ignition switch to OFF.
    3. Check the resistance between terminal 6 of the canister connector and the body ground.
      Fig 26: Checking Wire Harness And Connector (Pump Module - Ground)
      G04676496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result: 

      PUMP MODULE - GROUND

      Test Results Suspected Trouble Areas Proceed To
      Below 1 Ω Vacuum pump A
      10 kΩ or more Wire harness between vacuum pump and body ground B
    4. Reconnect the canister connector.

    A: Go to step   30 

    B: Go to step   32 

  26. INSPECT THROTTLE W/MOTOR BODY ASSY 
    1. Stop the engine.
    2. Disconnect the EVAP hose from the throttle body.
    3. Start the engine.
    4. Use your finger to confirm that the port of the throttle body has suction.

      Result: 

      THROTTLE W/MOTOR BODY ASSY

      Test Results Suspected Trouble Areas Proceed To
      Suction applied EVAP hose between throttle body and purge VSV A
      No suction Throttle body B

    A: Go to step   33 

    B: Go to step   34 

  27. 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.

    Go to step   37 

  28. REPLACE FUEL TANK CAP ASSY 

    HINT:

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

    Go to step   37 

  29. REPAIR EVAP LEAK PART 
    1. Prepare a rubber hose with a 15 to 18.5 mm inside diameter.
    2. Reinstall the fuel tank cap.
    3. Disconnect the atmospheric side hose of the pump module.
    4. Connect the rubber tube to the pump module.
    5. Using SST, pinch the rubber tube to close the canister passage to air.

      SST 00002-6872A

      Fig 27: Pinching Rubber Tube To Close Canister Passage To Air
      G04676497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect a pressure gauge (SST) to the service port (green cap near the air cleaner box).
      Fig 28: Connecting Pressure Gauge (SST) To Service Port
      G04676498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28 mmHg).
    8. Apply soapy water to the piping and connecting parts of the EVAP system. Look for areas where bubbles appear. This indicates leaking points.
    9. Repair or replace leaking point.

    HINT:

    • If the system has leaks, a whistling sound will be heard.
    • 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.

    Go to step   36 

  30. REPLACE CHARCOAL CANISTER ASSY 

    Go to step   37 

  31. REPLACE VACUUM SWITCHING VALVE ASSY NO. 1(PURGE VSV) 
    1. Disconnect the connector and the hoses from the purge VSV.
    2. Remove the purge VSV.
    3. Install a new purge VSV.
    4. Reconnect the connector and hoses.

    Go to step   37 

  32. REPAIR OR REPLACE WIRE HARNESS AND CONNECTOR 

    Go to step   37 

  33. REPLACE EVAP HOSE (THROTTLE BODY - PURGE VSV) 

    Go to step   37 

  34. INSPECT THROTTLE W/MOTOR BODY ASSY 
    1. Remove the throttle body (See REPLACEMENT ).
    2. Check that the EVAP purge port of the throttle body is not clogged. If necessary, replace the throttle body.

      Go to step   37 

  35. REPLACE ECM (See  REPLACEMENT  ) 

    Go to step   37 

  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.
  37. PERFORM EVAP SYSTEM CHECK (AUTO OPERATION) 
    NOTE:
    • In the EVAP SYSTEM CHECK (AUTO OPERATION), the series of 4 EVAP SYSTEM CHECK steps is performed automatically. It takes a maximum of approximately 15 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 and making the leak check of the fuel tank 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 EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F).
    1. Clear DTCs (See DTC CHECK/CLEAR ).
    2. On the hand-held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION.
    3. After the SYSTEM CHECK is completed, check for pending DTCs by selecting the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES.

    HINT:

    If no pending DTC is found, the repair has been successfully completed.

    38. COMPLETED 

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