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On-Vehicle Inspection

  1. INSPECT AIR-FUEL RATIO COMPENSATION SYSTEM 

    HINT: The system can be also checked by choosing "DATA MONITOR/02 SENSOR OUTPUT VOLTAGE" on the hand-held tester monitor.

    1. Connect the hand-held tester to terminals 23 (OXL1) and 7 (E1) and to terminals 21 (OXL2) and 7 (E1) of the ECM.
      Fig 1: Identifying Terminals OXL1, E1 & OXL2 Of ECM
      G03197058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      CAUTION: Connect test leads from the back side of the connector with the ECU connected.
    2. Warm up the heated oxygen sensor at 2,500 rpm of the engine speed for approximately 2 minutes.
    3. Confirm that the voltage varies between 0V and 1V at 2,500 rpm of the engine speed.

      OK : The voltage varies more than 8 times in 10 seconds. 

      CAUTION:
      • Perform the check immediately after warming up.
      • If the voltage variation could not be verified, warm up the heated oxygen sensor again.
  2. INSPECT FUEL CUT OFF RPM 
    1. Increase the engine speed to at least 3,500 rpm.
    2. Use a sound scope to check for injector operating sounds.
      3. Fig 2: Checking Injector Operating Sounds
      G03197059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check that the operating sounds stop momentarily and then resume when the throttle lever is released.

      HINT: Measure with the A/C OFF.

      Fuel return rpm: 1,400 rpm 

  3. VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS 
    1. Check for cracks or damage.

      HINT: Separation of the engine oil dipstick, oil filler cap, PCV hose, and etc. may cause the engine to run improperly. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run improperly.

      Fig 3: Inspecting Hoses, Connections & Gaskets
      G03197060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT EVAP SYSTEM LINE 
    1. Warm up the engine to the normal operating temperature.
    2. Stop the engine.
    3. Connect the vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge line.
      Fig 4: Connecting Vacuum Gauge To EVAP Service Port On Purge Line
      G03197061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. When using a hand-held tester: Force the VSV for EVAP to operate.
      1. Warm up the engine.
      2. Turn the ignition switch to OFF.
      3. Connect the hand-held tester or the OBD II scan tool to the DLC3.
      4. Turn the ignition switch to ON.
      5. Turn the hand-held tester or the OBD II scan tool ON.
      6. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV (ALONE).
        Fig 5: Connecting Hand-Held Tester Or OBD II Scan Tool To DLC3
        G03197062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. When not using a hand-held tester: Force the VSV for EVAP to operate.
      1. Disconnect the VSV for EVAP connector.
      2. Connect the positive (+) and negative (-) leads from the battery to the VSV for EVAP terminals.
      3. Start the engine.
        Fig 6: Connecting Positive (+) & Negative (-) Leads From Battery To VSV For EVAP Terminals
        G03197063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Check the vacuum at idle.
      Fig 7: Checking Vacuum At Idle
      G03197064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Vacuum: Minimum between 0.368 and 19.713 in.Hg (5 to 268 in.Ag) for over 5 seconds 

      HINT: If the vacuum does not change, the hose connecting the VSV to the service port is loose or blocked, or the VSV is malfunctioning.

    7. When using a hand-held tester:

      Return to the normal VSV for EVAP operation.

      1. Stop the engine.
      2. Disconnect the hand-held tester from the DLC3.
    8. When not using a hand-held tester:

      Return to the normal VSV for EVAP operation.

      1. Stop the engine.
      2. Disconnect the positive (+) and negative (-) leads from the VSV for EVAP terminal.
      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 8: Connecting Pressure Gauge To EVAP Service Port On Purge Line
      G03197065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. When using a hand-held tester:

      Force the VSV for CCV to operate.

      1. Warm up the engine.
      2. Turn the ignition switch to OFF.
      3. Connect the hand-held tester or the OBD II scan tool to the DLC3.
      4. Turn the ignition switch to ON.
      5. Turn the hand-held tester or the OBD II scan tool ON.
      6. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / CAN CTRL VSV.
        Fig 9: Connecting Hand-Held Tester Or OBD II Scan Tool To DLC3
        G03197066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: Do not start the engine.

        HINT: If the check is not completed within 10 minutes when the VSV for CCV is ON, the forced closure of the VSV for CCV will be reset.

    12. When not using a hand-held tester:

      Force the VSV for CCV to operate.

      1. Disconnect the VSV for CCV connector.
      2. Connect the positive (+) and negative (-) leads from the battery to the VSV for CCV terminals.
        Fig 10: Connecting Positive (+) & Negative (-) Leads From Battery To VSV For CCV Terminals
        G03197067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Check the pressure.
      1. Apply pressure (13.5 to 15.5 in.Ag) from the EVAP service port.

        Pressure: The gauge should be over 7.7 to 8.8 in.Ag for 2 minutes after the pressure is applied. 

        HINT: If pressure cannot be applied, it can be concluded that the hose connecting the VSV for the EVAP canister fuel tank has slipped off or the VSV is open.

        Fig 11: Checking Pressure
        G03197068Courtesy 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, then it can be concluded that the hose connecting the service port to the fuel tank is blocked, etc.

    14. When using the hand-held tester:

      Return to the normal VSV for CCV operation.

      1. Turn ignition switch OFF.
      2. Disconnect the hand-held tester from the DLC3.
        Fig 12: Checking Pressure (Pressure Decreases When Fuel Tank Cap)
        G03197069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    15. When not using the hand-held tester:

      Return to the 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.
  5. CHECK AIRTIGHTNESS IN FUEL TANK AND FILLER PIPE 
    1. Disconnect the EVAP line hose from the charcoal canister.
      1. Pinch portion A.
      2. Pull out the connector.
        Fig 13: Disconnecting EVAP Line Hose From Charcoal Canister
        G03197070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pressurize the internal pressure in the fuel tank to 4 kPa (41 gf/cm2 , 0.58 psi).
    3. Check that the internal pressure of the fuel tank can be held for 1 minute.
    4. Check the connected portions of each hose and pipe.
    5. Check the installed parts on the fuel tank and filler pipe. If there is abnormality, replace the fuel tank and filler pipe.
    6. Reconnect the EVAP line hose to the charcoal canister.
      Fig 14: Pressurizing Internal Pressure In Fuel Tank
      G03197071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSPECT FUEL CUT OFF VALVE AND FILL CHECK VALVE 
    1. Disconnect the purge line hose, EVAP line hose and air inlet hose from the charcoal canister.
    2. Holding the air inlet line.
    3. Pressurize 4 kPa (41 gf/cm2 , 0.58 psi) to the purge port and check that there is ventilation through the EVAP line hose.

      HINT: Check the fuel volume in the fuel tank if there is no ventilation in step (b). If the fuel is full, the EVAP line vent is closed by a float value of the fill check valve, therefore air cannot pass through the EVAP line hose. Reduce the fuel volume if necessary.

      Fig 15: Inspecting Fuel Cut Off Valve & Fill Check Valve
      G03197072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Check if there is anything stuck in the vent line hose and EVAP line hose.

      If there is nothing stuck in them, replace the fuel cut off valve and fill check valve.

    5. Reconnect the purge line hose and EVAP line hose to the charcoal canister.
  7. 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 hose to the charcoal canister.
      Fig 16: Checking Air Inlet Line
      G03197073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS 
    1. Measure the 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 

      3. Turn the ignition switch OFF.
        Fig 17: Measuring Power Source Voltage Of Vapor Pressure Sensor
        G03197074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the 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 18: Measuring Power Output Of Vapor Pressure Sensor
        G03197075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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