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Fuel EVAP System Test (Tacoma)

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 fuel EVAP system lines and connections for sharp bends or damage. Inspect fuel tank for damage, cracks 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 (00002-6872A-01) to EVAP service port. EVAP service port is located in purge vacuum hose for EVAP system near charcoal canister in engine compartment. See Figure and Figure .
  3. Operate EVAP Vacuum Switching Valve (VSV). If Toyota hand-held tester is available to operate EVAP VSV, go to next step. If Toyota hand-held tester is not available to operate EVAP VSV, go to step  5.
  4. Connect hand-held test to data link connector No. 3. See Figure. Start engine. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, activate EVAP VSV. Go to step  6.
  5. Disconnect electrical connector at EVAP VSV. EVAP VSV is bolted to end of charcoal canister and contains Black 2-pin electrical connector with White/Red and White/Green wires. See Figure and 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 reading should be.368-19.713 in. Hg (5.00-268.00 in. H2O) for over 5 seconds. If vacuum reading 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 hand-held tester to operate EVAP VSV, stop operation of EVAP VSV. Remove hand-held tester. 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 engine compartment. See Figure and Figure .
  9. Apply 13.5-15.5 in. H2O of pressure to EVAP service port. After 2 minutes of applying pressure, 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. 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 hose crimper and pressure gauge. Go to next step. If pressure does not decrease when fuel tank cap is removed, remove hose crimper and pressure gauge. Check for restricted vacuum hose between EVAP service port, charcoal canister and fuel tank. Repair or replace vacuum hose as necessary.
  11. To check charcoal canister, disconnect necessary electrical connectors and components for removal of charcoal canister. Remove charcoal canister. Inspect charcoal canister for cracks or damage. If charcoal canister is okay, go to next step. If charcoal canister is defective, replace charcoal canister.
  12. Install plugs on ports "A" and "B" on charcoal canister. See Fig 2. Apply.21 psi (.015 kg/cm2 ) air pressure to port "D" while holding port "C" closed. See Fig 2. Ensure air flows freely from port "E".
  13. Apply.21 psi (.015 kg/cm2 ) air pressure to port "D" while holding ports "C" and "E" closed. See Fig 2. Ensure air does not flow from port "F".
  14. Using vacuum pump, apply.87 in. Hg of vacuum to port "C". Ensure vacuum does not decrease when port "F" is closed and that vacuum decreases when port "F" is opened.
  15. While holding port "F" closed, use vacuum pump to apply.87 in. Hg of vacuum to port "D". Ensure vacuum does not decrease when port "C" is closed and that vacuum decreases when port "C" is opened. Replace charcoal canister if defective.
  16. Reinstall charcoal canister. If fuel EVAP system operates properly, it may be necessary to check operation of EVAP 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 (Tacoma)
    G00028698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Identifying Charcoal Canister Ports (Tacoma)
    G98A11882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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