Inspection Procedure

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

HINT:

Using Techstream monitor results enable the EVAP 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).
6. Enter the following menus: 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 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.

Fig 1: DTC Chart
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
PERFORM EVAP SYSTEM CHECK (AUTOMATIC MODE)
NOTE:
- In the Evaporative System Check (Automatic Mode), the series of 5 Evaporative System Check step are performed automatically. 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 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 Evaporative System Check, keep the temperature below 35°C (95°F).
1. Clear the DTCs (See DTC CHECK/CLEAR ).
2. Enter the following menus: 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: Powertrain / Engine and ECT / Trouble Codes / Pending.
  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.
PERFORM EVAP SYSTEM CHECK (MANUAL MODE)

Fig 2: EVAP System - Driving Pattern (Manual Mode)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- In the Evaporative System Check (Manual Mode), the series of 5 Evaporative System Check step are performed manually.
- 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 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 Evaporative System Check, keep the temperature below 35°C (95°F).
1. Clear the DTCs (See DTC CHECK/CLEAR ).
2. Enter the following menus: Powertrain / Engine and ECT / Utility / Evaporative System Check / Manual Mode.

PERFORM EVAP SYSTEM CHECK (STEP 1/5)

Fig 3: EVAP System - Driving Pattern (Step 1/5)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 1/5.

Result

RESULT CHART

DTC No. ⁽¹⁾

Test Result

Suspected Trouble Area

Proceed to

Virtually no variation in EVAP pressure

Not yet determined

P0451

EVAP pressure fluctuates by +-0.3 kPa (2.25 mmHg) or more

Pressure sensor noise

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

B: Go to step 30

A: Go to Next Step

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

Fig 4: EVAP System - Driving Pattern (Step 1/5 To 2/5)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Result

RESULT CHART

DTC No. ⁽¹⁾

Test Result

Suspected Trouble Area

Proceed to

Virtually no variation in EVAP pressure during step 1/5. Then decreases to 0.02 Inch leak pressure standard

Not yet determined

P2402

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

Vacuum pump stuck ON

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

HINT:

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

B: Go to step 23

A: Go to Next Step

PERFORM EVAP SYSTEM CHECK (STEP 2/5)

Fig 5: EVAP System - Driving Pattern (Step 2/5)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Make a note of the pressures checked in the steps below.

Check the EVAP pressure 4 seconds after the vacuum pump is activated*.
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

RESULT CHART

DTC No. ⁽¹⁾

Test Result

Suspected Trouble Area

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

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

P043E

EVAP pressure in step (b) below -4.85 kPa (-36.38 mmHg)

0.02 Inch orifice clogged

P2419

EVAP pressure in step (a) more than -1.06 kPa (-7.95 mmHg)

Vent valve stuck closed

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

B: Go to step 11

C: Go to step 30

D: Go to step 19

A: Go to Next Step

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

Fig 6: EVAP System - Driving Pattern (Step 2/5 To 3/5)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 3/5.

Result

RESULT CHART

DTC No. ⁽¹⁾

Test Result

Suspected Trouble Area

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

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

Pressure sensor malfunction (stuck)

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

B: Go to step 20

C: Go to step 30

A: Go to Next Step

PERFORM EVAP SYSTEM CHECK (STEP 3/5)

Fig 7: EVAP System - Driving Pattern (Step 3/5)
Courtesy 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 15 minutes.

PERFORM EVAP SYSTEM CHECK (STEP 4/5)

Fig 8: EVAP System - Driving Pattern (Step 4/5)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 4/5.

Result

RESULT CHART

DTC No. ⁽¹⁾

Test Result

Suspected Trouble Area

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

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 EVAP VSV and intake manifold

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

EVAP VSV stuck closed

⁽¹⁾	The DTCs related to the EVAP system are 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)

Fig 9: EVAP System - Driving Pattern (Step 5/5)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 5/5.
Compare the EVAP pressure in step 3/5 and the second 0.02 inch leak pressure standard (step 5/5).

Result

RESULT CHART

DTC No. ⁽¹⁾

Test Result

Suspected Trouble Area

Proceed to

EVAP pressure (step 3/5) lower than second 0.02 Inch leak pressure standard (step 5/5)

Not yet determined

P0441 and P0455

EVAP pressure (step 3/5) higher than [second 0.02 Inch leak pressure standard (step 5/5) x 0.2]

EVAP VSV stuck open
EVAP gross leak

P0456

EVAP pressure (step 3/5) higher than second 0.02 Inch leak pressure standard (step 5/5)

EVAP small leak

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

A: Go to step 36

B: Go to step 12

C: Go to Next Step

PERFORM EVAP SYSTEM CHECK (STEP 3/5)

Fig 10: EVAP System - Driving Pattern (Step 3/5)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 3/5.

Result

RESULT CHART

DTC No. ⁽¹⁾

Test Result

Suspected Trouble Area

Proceed to

P043F

EVAP pressure less than [0.02 inch leak pressure standard] measured at 2/5

0.02 inch orifice high-flow

P2401

EVAP pressure almost same as [0.02 inch leak pressure standard] measured at 2/5

Vacuum pump stuck OFF

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

HINT:

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

A: Go to step 30

B: Go to step 23

PERFORM ACTIVE TEST BY TECHSTREAM (EVAP VSV)

Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VSV for EVAP Control.
Disconnect the hose (connected to the canister) from the EVAP VSV.
Turn the engine switch on (IG).
Using the tester, turn the EVAP VSV OFF.
Use your finger to confirm that the EVAP VSV has no suction.
Using the tester, turn the EVAP VSV ON.
Use your finger to confirm that the EVAP VSV has suction.

Fig 11: Identifying EVAP VSV Hose

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT CHART

Test Result	Suspected Trouble Area	Proceed to
No suction when EVAP VSV turned OFF, and suction applied when turned ON	EVAP VSV normal	A
Suction applied when EVAP VSV turned OFF	EVAP VSV stuck open	B
No suction when EVAP VSV turned ON	EVAP VSV stuck closed Problems with EVAP hose between EVAP VSV and Intake manifold	C

B: Go to step 14

C: Go to step 15

A: Go to Next Step

CHECK FUEL TANK CAP

Check that the fuel tank cap is correctly installed.
Confirm that the fuel lank 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.

Remove the fuel tank cap and install it onto the fuel tank 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 tank cap is normal.

Result

RESULT CHART

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
No fuel tank cap	-	C

A: Go to step 29

B: Go to step 27

C: Go to step 28

INSPECT DUTY VACUUM SWITCHING VALVE (EVAP VSV)

Turn the engine switch off.
Disconnect the E15 EVAP VSV connector.
Disconnect the hose (connected to the canister) from the EVAP VSV.
Start the engine.
Use your finger to confirm that the EVAP VSV has no suction.

Result

RESULT CHART

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

Fig 12: Identifying EVAP VSV Hose And Clamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

A: Go to step 35

B: Go to step 31

CHECK EVAP HOSE (EVAP VSV - THROTTLE BODY)

Disconnect the hose (connected to the throttle body) from the EVAP VSV.
Turn the engine switch on (IG).

Use your finger to confirm that the hose has suction.

Result

RESULT CHART

Test Result	Suspected Trouble Area	Proceed to
Suction applied	EVAP hose between EVAP VSV and throttle body normal	A
No suction	Intake manifold port EVAP hose between EVAP VSV and throttle body	B

Reconnect the hose.

Fig 13: Disconnecting Hose (Connected To Throttle Body) From EVAP VSV

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

B: Go to step 26

A: Go to Next Step

INSPECT DUTY VACUUM SWITCHING VALVE (EVAP VSV)

Remove the EVAP VSV connector.
Apply battery voltage to the terminals of the EVAP VSV.

Using compressed air, confirm that air flows from port A to port B.

Result

RESULT CHART

Test Result	Suspected Trouble Area	Proceed to
Air flows	EVAP VSV normal	A
No air flows	EVAP VSV	B

Install the EVAP VSV.

Fig 14: Inspecting Duty Vacuum Switching Valve (EVAP VSV)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

B: Go to step 31

A: Go to Next Step

CHECK HARNESS AND CONNECTOR (POWER SOURCE OF EVAP VSV)

Disconnect the E15 EVAP VSV connector.
Turn the engine switch on (IG).

Measure the voltage between terminal 1 of EVAP VSV connector and body ground.

Result

RESULT CHART

Test Result	Suspected Trouble Area	Proceed to
Between 11V and 14 V	Normal	A
Other than result above	Wire harness or connectors between EVAP VSV and ECM	B

Reconnect the EVAP VSV connector.

Fig 15: Identifying E15 EVAP VSV Connector

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

B: Go to step 32

A: Go to Next Step

CHECK HARNESS AND CONNECTOR (EVAP VSV - ECM)

Disconnect the E3 ECM connector and the E15 EVAP VSV connector.

Measure the resistance according to the value (s) in the table below.

Standard resistance

RESISTANCE SPECIFICATION CHART

Tester Connection	Specified Condition
E3-11 (PRG) - E15-2	Below 1 Ω
E3-11 (PRG) - Body ground	10 kΩ or higher
E15-2 - Body ground	10 kΩ or higher

Reconnect the EVAP VSV connector.
Reconnect the ECM connector.

Fig 16: Identifying E3 ECM Connector And E15 EVAP VSV Connector

OK: Go to step 35

NG: Go to step 32

PERFORM ACTIVE TEST BY TECHSTREAM (FOR VENT VALVE)

Turn the engine switch on (IG).
Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VSV for Vent Valve.
Measure the voltage between terminal VPMP of the ECM connector and body ground when the vent valve is turned ON (close) and OFF (vent) using the tester.

Result

RESULT CHART

Test Result	Suspected Trouble Area	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

Fig 17: Identifying ECM Connector A6

A: Go to step 22

B: Go to step 35

PERFORM ACTIVE TEST BY TECHSTREAM (FOR VENT VALVE)

Turn the engine switch on (IG).
Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VSV for Vent Valve.
Measure the voltage between terminal VPMP of the ECM connector and body ground when the vent valve is turned ON (close) and OFF (vent) using the tester.

Result

RESULT CHART

Test Result	Suspected Trouble Area	Proceed to
Between 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

Fig 18: Identifying ECM Connector A6

B: Go to step 22

C: Go to step 35

A: Go to Next Step

INSPECT CANISTER ASSEMBLY (POWER SOURCE FOR VENT VALVE)

Turn the engine switch off.
Disconnect the Q49 canister pump module connector.
Turn the engine switch on (IG).

Measure voltage between terminal 9 of the canister connector and body ground.

Result

RESULT CHART

Test Result	Suspected Trouble Area	Proceed to
Between 9 V and 14 V	Normal	A
Between 0 V and 3 V	Power source wire harness of vent valve	B

Reconnect the canister pump module connector.

Fig 19: Identifying Q49 Canister Pump Module Connector

B: Go to step 32

A: Go to Next Step

INSPECT CANISTER ASSEMBLY (VENT VALVE OPERATION)

Turn the engine switch off.
Disconnect the Q49 canister pump module connector.
Apply the battery voltage to terminals 9 and 8 of the pump module.

Touch the pump module to confirm the vent valve operation.

Result

RESULT CHART

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

Reconnect the canister pump module connector.

Fig 20: Inspecting Canister Assembly (Vent Valve Operation)

A: Go to step 32

B: Go to step 30

PERFORM ACTIVE TEST BY TECHSTREAM (FOR PUMP MODULE (VACUUM CAP))

Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the Vacuum Pump.
Measure the voltage between MPMP terminal of ECM connector and body ground when the vacuum pump is turned ON and OFF using the tester.

Result

RESULT CHART

Test Result	Suspected Trouble Area	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

Fig 21: Identifying ECM Connector A6

B: Go to step 35

A: Go to Next Step

CHECK HARNESS AND CONNECTOR (PUMP MODULE - ECM)

Turn the engine switch off.
Disconnect the Q49 canister pump module connector.
Turn the engine switch on (IG).
On Techstream, enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the Vacuum Pump.
Turn the vacuum pump ON.

Measure the voltage between terminal 1 of the canister connector and body ground.

Result

RESULT CHART

Test Result	Suspected Trouble Area	Proceed to
Between 9 V and 14 V	Normal	A
Between 0 V and 3 V	Wire harness between ECM and vacuum pump	B

Reconnect the canister pump module connector.

Fig 22: Identifying Q49 Canister Pump Module Connector

B: Go to step 32

A: Go to Next Step

CHECK HARNESS AND CONNECTOR (PUMP MODULE - GROUND)

Turn the engine switch off.
Disconnect the Q49 canister pump module connector.

Measure the resistance between terminal 6 of the canister connector and body ground.

Result

RESULT CHART

Test Result	Suspected Trouble Area	Proceed to
Below 1 Ω	Vacuum Pump	A
10 kΩ or higher	Wire harness between vacuum pump and body ground	B

Reconnect the canister pump module connector.

Fig 23: Identifying Q49 Canister Pump Module Connector

A: Go to step 30

B: Go to step 32

INSPECT THROTTLE BODY (EVAP PURGE PORT)

Turn the engine switch off.
Disconnect the EVAP hose from the intake manifold.
Turn the engine switch on (IG).

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

Result

RESULT CHART

Test Result	Suspected Trouble Area	Proceed to
Suction applied	EVAP hose between intake manifold and EVAP VSV	A
No suction	Intake manifold	B

Reconnect the EVAP hose.

A: Go to step 33

B: Go to step 34

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 37
REPLACE FUEL TANK CAP
HINT:

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

NEXT: Go to step 37
REPAIR EVAP LEAK PART
1. Disconnect the pressure gauge to the canister with the adapter.
  
  Fig 24: Identifying Air Filter And Canister
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the pressure gauge to the canister with the adapter.
  
  Fig 25: Connecting Pressure Gauge To Canister With Adapter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, pinch the rubber tube to close the canister passage to air.
4. Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28 mmHg).
5. Apply soapy water to the piping and connecting parts of the EVAP system. Check for areas where bubbles appear. This indicates leaking points.
6. Repair or replace leaking parts.
  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.
NEXT: Go to step 37
REPLACE CANISTER
NEXT: Go to step 37
REPLACE DUTY VACUUM SWITCHING VALVE (EVAP VSV)
1. Disconnect the connector and hoses from the EVAP VSV.
2. Remove the EVAP VSV.
3. Install a new EVAP VSV.
4. Reconnect the connector and hoses.
NEXT: Go to step 37
REPAIR OR REPLACE HARNESS OR CONNECTOR
NEXT: Go to step 37
REPLACE EVAP HOSE (THROTTLE BODY - EVAP VSV)
NEXT: Go to step 37
INSPECT THROTTLE BODY (EVAP PURGE PORT)
1. Remove the throttle body.
2. Check that the EVAP purge port of the throttle body is not clogged. If necessary, replace the throttle body.
NEXT: Go to step 37
REPLACE ECM
NEXT: Go to step 37
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 37
PERFORM EVAP SYSTEM CHECK (AUTOMATIC MODE)
HINT:
- In the Evaporative System Check (Automatic Mode), the series of 5 Evaporative System Check step are performed automatically. 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 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 Evaporative System Check, keep the temperature below 35°C (95°F).
1. Clear the DTCs (See DTC CHECK/CLEAR ).
2. On Techstream, enter the following menus: 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: Powertrain / Engine and ECT / Trouble Codes / Pending.
  HINT:
  
  If no pending DTC is found, the repair has been successfully completed.
  
  NEXT: END