EVAP System: Procedure

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 Techstream to the DLC3.
5. Turn the ignition switch ON.
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: DTCs & Malfunctioning Areas Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NEXT: Go to next step
PERFORM EVAPORATIVE SYSTEM CHECK (AUTOMATIC MODE)
NOTE:
- In the Evaporative System Check (Automatic Mode), the series of 5 Evaporative System Check steps 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 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 Evaporative System Check, keep the temperature below 35°C (95°F).
1. Clear the DTCs. Refer to 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.
NEXT: Go to next step
PERFORM EVAPORATIVE SYSTEM CHECK (MANUAL MODE)

Fig 2: Performing Evaporative System Check (Manual Mode)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- In the Evaporative System Check (Manual Mode), the series of 5 Evaporative System Check steps 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 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 Evaporative System Check, keep the temperature below 35°C (95°F).
1. Clear the DTCs. Refer to DTC CHECK / CLEAR .
2. Enter the following menus: Powertrain / Engine and ECT / Utility / Evaporative System Check / Manual Mode.
NEXT: Go to next step

PERFORM EVAPORATIVE SYSTEM CHECK (STEP 1/5)

Fig 3: EVAP Pressure Graph (Step 1)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 1/5.

Result

DTC No. *	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	B

HINT:

*: The DTCs related to the EVAP system are displayed on the Techstream when checking.

B → See step 29

A: Go to next step

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

Fig 4: EVAP Pressure Graph (Step 1 To 2)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Result

DTC No. *	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

HINT:

*: The DTCs related to the EVAP system are displayed on the Techstream when checking.
The first 0.02 inch leak criterion is the value determined in step 2/5.

B → See step 22

A: Go to next step

PERFORM EVAPORATIVE SYSTEM CHECK (STEP 2/5)

Fig 5: EVAP Pressure Graph (Step 2)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

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

(a) 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.
(b) Check the EVAP pressure again when it has stabilized. This pressure is the 0.02 inch leak criterion.

Result

DTC No. *	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

HINT:

*: The DTCs related to the EVAP system are displayed on the Techstream when checking.

D → See step 19

C → See step 29

B → See step 11

A: Go to next step

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

Fig 6: EVAP Pressure Graph (Step 2 To 3)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 3/5.

Result

DTC No. *	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	C

HINT:

*: The DTCs related to the EVAP system are displayed on the Techstream when checking.

C → See step 29

B → See step 19

A: Go to next step

PERFORM EVAPORATIVE SYSTEM CHECK (STEP 3/5)

Fig 7: EVAP Pressure Graph (Step 3)
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 900 seconds (15 minutes).
NEXT: Go to next step

PERFORM EVAPORATIVE SYSTEM CHECK (STEP 4/5)

Fig 8: EVAP Pressure Graph (Step 4)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 4/5.

Result

DTC No. *	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

HINT:

*: The DTCs related to the EVAP system are displayed on the Techstream when checking.

C → See step 12

B → See step 15

A: Go to next step

PERFORM EVAPORATIVE SYSTEM CHECK (STEP 5/5)

Fig 9: EVAP Pressure Graph (Step 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 criterion (step 5/5).

Result

DTC No. *	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	B

HINT:

*: The DTCs related to the EVAP system are displayed on the Techstream when checking.

B → See step 12

A → See step 35

PERFORM EVAPORATIVE SYSTEM CHECK (STEP 3/5)

Fig 10: EVAP Pressure Graph (Step 3)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 3/5.

Result

DTC No. *	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

HINT:

*: The DTCs related to the EVAP system are displayed on the Techstream when checking.
The first 0.02 inch leak criterion is the value determined in step 2/5.

B → See step 22

A → See step 29

PERFORM ACTIVE TEST USING TECHSTREAM (PURGE VSV)

Fig 11: Disconnecting Hose From Purge VSV

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Enter the following menus: Powertrain / Engine / Active Test / Activate the VSV for EVAP Control.
Disconnect the hose (connected to the canister) from the purge VSV.
Start the engine.
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

Test 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 purge line hose between purge VSV and intake manifold	C

C → See step 15

B → See step 14

A: Go to next step

CHECK FUEL TANK CAP

Check that the fuel tank cap is correctly installed and confirm the fuel cap meets OEM specification.
1. Tighten the fuel tank cap until a few click sounds are heard.
HINT:

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

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

C → See step 27

B → See step 26

A → See step 28

INSPECT PURGE VSV

Fig 12: Disconnecting Purge Line Hose & V4 Purge VSV Connector

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Turn the ignition switch OFF.
Disconnect the V4 purge VSV connector.
Disconnect the purge line hose (connected to the canister) from the purge VSV.
Start the engine.

Use your finger to confirm that the purge VSV has no suction.

Result

Test Results	Suspected Trouble Areas	Proceed to
No suction	ECM	A
Suction applied	Purge VSV	B

B → See step 30

A → See step 34

CHECK PURGE LINE HOSE (PURGE VSV - INTAKE MANIFOLD)

Fig 13: Disconnecting Purge Line Hose From Purge VSV

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Disconnect the purge line hose (connected to the intake manifold) from the purge VSV.
Start the engine.

Use your finger to confirm that the hose has suction.

Result

Test Results	Suspected Trouble Areas	Proceed to
Suction applied	Purge line hose between purge VSV and intake manifold normal	A
No suction	Intake manifold port Purge line hose between purge VSV and intake manifold	B

B → See step 25

A: Go to next step

INSPECT PURGE VSV

Fig 14: Inspecting Purge VSV

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Disconnect the V4 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

Test Results	Suspected Trouble Areas	Proceed to
Air flows	Purge VSV normal	A
No air flows	Purge VSV	B

B → See step 30

A: Go to next step

CHECK WIRE HARNESS (POWER SOURCE OF PURGE VSV)

Fig 15: Identifying V4 Purge VSV Connector

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Disconnect the V4 purge VSV connector.
Turn the ignition switch ON.

Measure the voltage of the wire harness side connector.

Result

Tester Connection	Test Results	Suspected Trouble Areas	Proceed to
V4-1 - V4-2	Between 11 V and 14 V	Normal	A
V4-1 - V4-2	Other than result above	Wire harness or connectors between purge VSV and ECM	B

B → See step 31

A: Go to next step

CHECK WIRE HARNESS (PURGE VSV - ECM)

Fig 16: Checking Wire Harness (Purge VSV - ECM)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Disconnect the V4 purge VSV connector.
Disconnect the E2 ECM connector.

Measure the resistance of the wire harness side connectors.

Standard resistance

Tester Connection	Specified Condition
V4-1 - E2-11 (PRG)	Below 1 Ω
V4-1 or E2-11 (PRG) - Body ground	10 kΩ or higher

NG → See step 31

OK → See step 34

PERFORM ACTIVE TEST USING TECHSTREAM (FOR VENT VALVE)

Fig 17: Identifying Terminal VPMP Of E5 ECM Connector

Turn the ignition switch ON.
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 the body ground when the vent valve is turned ON (closed) and OFF (vent) using the tester.

Result

Tester Connection	Test Results	Suspected Trouble Areas	Proceed to
E5-12 (VPMP) - Body ground	Below 3 V when OFF and ON	Power source of vent valve	A
E5-12 (VPMP) - Body ground	Between 11 V and 14 V when OFF Below 3 V when ON	Vent valve	B
E5-12 (VPMP) - Body ground	Between 11 V and 14 V when OFF and ON	ECM	C

C → See step 34

B → See step 21

A: Go to next step

INSPECT CANISTER PUMP MODULE (POWER SOURCE FOR VENT VALVE)

Fig 18: Identifying C12 Canister Pump Module Connector Terminals

Turn the ignition switch OFF.
Disconnect the C12 canister pump module connector.
Turn the ignition switch ON.

Measure the voltage of the wire harness side connector.

Result

Tester Connection	Test Results	Suspected Trouble Areas	Proceed to
C12-9 (+B) - Body ground	11 V to 14 V	Normal	A
C12-9 (+B) - Body ground	0 V to 3 V	Power source wire harness of vent valve	B

B → See step 31

A: Go to next step

INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION)

Fig 19: Applying Battery Voltage To Terminals 9 And 8 Of Canister Pump Module

Turn the ignition switch OFF.
Disconnect the C12 canister pump module 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.

Result

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

B → See step 29

A → See step 31

PERFORM ACTIVE TEST USING TECHSTREAM (FOR CANISTER PUMP MODULE [LEAK DETECTION PUMP])

Fig 20: Identifying MPMP Terminal Of E5 ECM Connector

Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the Vacuum Pump.

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

Tester Connection	Test Results	Suspected Trouble Areas	Proceed to
E5-5 (MPMP) - Body ground	0 V to 3 V when OFF 11 V to 14 V when ON	ECM normal	A
E5-5 (MPMP) - Body ground	11 V to 14 V when OFF 0 V to 3 V when ON	ECM	B

B → See step 34

A: Go to next step

CHECK WIRE HARNESS (CANISTER PUMP MODULE - ECM)

Fig 21: Identifying C12 Canister Pump Module Connector Terminals

Turn the ignition switch OFF.
Disconnect the C12 canister pump module connector.
Turn the ignition switch ON.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the Vacuum Pump.
Turn the leak detection pump ON.

Measure the voltage of the wire harness side connector.

Result

Tester Connection	Test Results	Suspected Trouble Areas	Proceed to
C12-1 (+B) - Body ground	11 V to 14 V	Normal	A
C12-1 (+B) - Body ground	0 V to 3 V	Wire harness between ECM and leak detection pump	B

B → See step 31

A: Go to next step

CHECK WIRE HARNESS (CANISTER PUMP MODULE - GROUND)

Fig 22: Identifying C12 Canister Pump Module Connector Terminals

Disconnect the C12 canister pump module canister connector.
Turn the ignition switch OFF.

Measure the resistance of the wire harness side connectors between terminal 6 of the C12 connector and the body ground.

Result

Tester Connection	Test Results	Suspected Trouble Areas	Proceed to
C12-6 (GND) - Body ground	Below 1 Ω	Leak detection pump	A
C12-6 (GND) - Body ground	10 kΩ or higher	Wire harness between leak detection pump and body ground	B

B → See step 31

A → See step 29

INSPECT INTAKE MANIFOLD (EVAP PURGE PORT)

Turn the ignition switch OFF.
Disconnect the purge line 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

Test Results	Suspected Trouble Areas	Proceed to
Suction applied	purge line hose between intake manifold and purge VSV	A
No suction	Intake manifold	B

B → See step 33

A → See step 32

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 cap that meets OEM specifications, and tighten it until a few click sounds are heard.
NEXT → See step 36
REPLACE FUEL TANK CAP
HINT:

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

NEXT → See step 36
LOCATE EVAP LEAK
1. Disconnect the vent hose.
  
  Fig 23: Disconnecting Vent Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the EVAP pressure tester tool to the vent hose with the adapter.
  
  Fig 24: Installing EVAP Pressure Tester Tool To Vent Hose With Adapter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 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 → See step 36
REPLACE CANISTER ASSEMBLY
1. Replace the canister assembly. Refer to REMOVAL .
  NOTE:
  When replacing the canister, check the canister pump module interior and related pipes for water, fuel or 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 25: Identifying Inspection Areas For Canister Assembly Replacement
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NEXT → See step 36
REPLACE PURGE VSV
1. Disconnect the connector and hoses from the purge VSV.
2. Remove the purge VSV.
3. Install a new purge VSV.
  
  Fig 26: Identifying Purge VSV
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Reconnect the connector and hose.
NEXT → See step 36
REPAIR OR REPLACE HARNESS AND CONNECTOR
NEXT → See step 36
REPLACE PURGE LINE HOSE (INTAKE MANIFOLD - PURGE VSV)
NEXT → See step 36
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 → See step 36
REPLACE ECM
1. Replace the ECM.
NEXT → See step 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.
NEXT → See step 36
PERFORM EVAPORATIVE SYSTEM CHECK (AUTOMATIC MODE)
NOTE:
- In the Evaporative System Check (Automatic Mode), the series of 5 Evaporative System Check steps 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 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 Evaporative System Check, keep the temperature below 35°C (95°F).
1. Clear the DTCs. Refer to 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 found, the repair has been successfully completed.
NEXT → COMPLETED