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Home >> Toyota >> 1999 >> RAV4 Base, 4D Utility, AWD, Standard >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - System & Component Testing - 4-Cylinder >> Emission Systems & Sub-Systems >> Fuel Evaporation System >> Fuel EVAP System Test (RAV4)
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Fuel EVAP System Test (RAV4)

NOTE: Manufacturer provides testing information for testing airtightness of fuel tank and components along with testing of charcoal canister and fuel EVAP system.
  1. Inspect all lines and connections for sharp bends or damage. Fuel inlet pipe may also be referred to as fuel filler pipe. Inspect fuel inlet pipe for cracks, damage or fuel leakage. Inspect fuel tank cap for cracks or deformed gasket. Replace components if defective or damaged.
  2. Start engine and warm engine to normal operating temperature. Shut engine off. Connect vacuum gauge from EVAP system test kit to EVAP service port. EVAP service port is located in engine compartment, in purge vacuum hose for EVAP system. See Figure.
  3. EVAP Vacuum Switching Valve (VSV) must be operated. If scan tool is available, go to next step. If scan tool is not available, go to step  5.
  4. Connect scan tool to data link connector No. 3. See Figure. Start engine. Turn scan tool on. Select ACTIVE TEST MODE on scan tool. Using scan tool manufacturer's instructions, activate EVAP VSV. Go to step  6.
  5. Disconnect electrical connector at EVAP VSV. EVAP VSV is located on bracket near rear of air filter housing and contains Black 2-pin electrical connector with Black/Red and Pink wires. See Figure. Using jumper wires, connect battery voltage and ground to electrical terminals on EVAP VSV to operate EVAP VSV. Start engine. Go to next step.
  6. Check vacuum reading on vacuum gauge with engine idling. Vacuum should be.368-19.713 in Hg. or (5-268 in. H2O) for over 5 seconds. If vacuum is within specification, go to next step. If vacuum reading is not within specification, check for loose or restricted vacuum hose to EVAP service port, or for malfunctioning EVAP VSV. To check EVAP VSV operation, see EVAP VACUUM SWITCHING VALVE .
  7. Shut engine off. If using scan tool to operate EVAP VSV, stop operation of EVAP VSV. Remove scan tool. Go to next step. If connecting battery voltage to EVAP VSV to operate EVAP VSV, disconnect jumper wires and reconnect electrical connector on EVAP VSV. Go to next step.
  8. Disconnect vacuum gauge from EVAP service port. Connect pressure gauge to EVAP service port. Install hose crimper on air drain hose near charcoal canister. See Fig 1. Charcoal canister is located in the engine compartment. See Figure.
  9. Apply 13.5-15.5 in. H2O of pressure to EVAP service port. After 2 minutes of applying the pressure, the pressure should be 7.7-8.8 in. H2O. If pressure is within specification, remove hose crimper and go to next step. If pressure cannot be maintained, remove hose crimper and check for disconnected vacuum hose between EVAP VSV, charcoal canister and fuel tank. If vacuum hose is properly installed on EVAP VSV, charcoal canister and fuel tank, check for stuck open EVAP VSV. To check EVAP VSV operation, see EVAP VACUUM SWITCHING VALVE .
  10. With pressure still applied at EVAP service port, remove fuel tank cap and note pressure reading. Pressure should decrease when fuel tank cap is removed. If pressure decreases when fuel tank cap is removed, remove pressure gauge and go to next step. If pressure does not decrease when fuel tank cap is removed, remove pressure gauge and check for restricted vacuum hose between EVAP service port, charcoal canister and fuel tank. Repair or replace vacuum hose as necessary.
  11. Disconnect necessary electrical connectors and components for removal of charcoal canister. Remove charcoal canister. Inspect charcoal canister for cracks or damage at all hose fittings. If charcoal canister is okay, go to next step. If charcoal canister is defective, replace charcoal canister.
  12. Install plug on port "E" on charcoal canister. See Fig 2. Check for clogged filter and/or stuck check valve and diaphragm by applying.26 psi (.018 kg/cm2 ) air pressure to port "A" while holding port "B" closed. See Fig 2. Ensure air flows freely from port "D".
  13. Apply.26 psi (.018 kg/cm2 ) air pressure to port "A" while holding ports "B" and "D" closed. See Fig 2. Ensure no air flows from port "C".
  14. Using vacuum pump, apply 1.01 in. Hg of vacuum to port "B". Ensure vacuum does not decrease when port "C" is closed and that vacuum decreases when port "C" is opened. See Fig 2.
  15. While holding port "C" closed, use vacuum pump to apply.36 in. Hg of vacuum to port "A". Ensure air flows into "B". See Fig 2. Replace charcoal canister if defective.
  16. Reinstall charcoal canister. If fuel EVAP system operates properly, it may be necessary to check operation of EVAP Vacuum Switching Valve (VSV), vapor pressure sensor and vapor pressure sensor Vacuum Switching Valve (VSV). See EVAP VACUUM SWITCHING VALVE , VAPOR PRESSURE SENSOR  and VAPOR PRESSURE SENSOR VACUUM SWITCHING VALVE .
    Fig 1: Installing Hose Crimper On Air Drain Hose (RAV4)
    G99H08721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Identifying Charcoal Canister Ports (RAV4)
    G98J11881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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