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On-Vehicle Inspection

WARNING: This page is about a different car, the 2006 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

(2005/05-2006/01)

  1. VISUALLY CHECK HOSES, CONNECTORS AND GASKETS 
    1. Check that there are no cracks, leaks or damage.
      NOTE:
      • Detachment or other problems with the engine oil dipstick, filler cap, PCV hose and other components 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 an engine failure or engine failure malfunctions.
      Fig 1: Checking For Looseness & Cracks
      G04436079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the result is not as specified, replace parts as necessary.

  2. CHECK FUEL CUT OFF RPM 
    1. Start and warm up the engine.
    2. Open the throttle valve and keep the engine speed at 3,000 RPM.
    3. Use a sound scope to check for injector operating noise.
    4. Check that when the accelerator pedal is released, injector operation noise stops momentarily and then resumes. If the result is not specified, check the injector, wiring and ECM.
  3. CHECK LINE AND CONNECTORS 
    1. Visually check for loose connections, sharp bends or damage.
  4. CHECK FUEL TANK ASSEMBLY 
    1. Visually check for deformations, cracks or fuel leakage.
  5. CHECK EVAP SYSTEM LINE 
    1. Warm up the engine to normal operating temperature and stop the engine.
    2. Install a vacuum gauge (EVAP control system test equipment vacuum gauge) into the EVAP service port on the purge line.
      Fig 2: Installing Vacuum Gauge (EVAP Control System Test Equipment Vacuum Gauge) Into EVAP Service Port On Purge Line
      G04436080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. When using the intelligent tester:

      Operation of the purge VSV.

      1. Connect the intelligent tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the DLC3.
      2. Start the engine.
      3. Turn the intelligent tester main switch ON.
      4. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / PURGE VSV (ALONE).
    4. When not using the intelligent tester:

      Operation of the purge VSV.

      1. Disconnect the purge VSV connector.
      2. Connect leads from the positive (+) and negative (-) battery terminals to the purge VSV terminals.
      3. Start the engine.
        Fig 3: Connecting CAN VIM To DLC3
        G04436081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Check the vacuum when the engine idles.

      Standard vacuum: Maintain between 0.368 and 19.713 in.Hg (5 to 268 in.Aq) for over 5 seconds. 

      HINT:

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

    6. When using the intelligent tester:

      Conclude operation of the purge VSV.

      Fig 4: Connecting Pressure Gauge To EVAP Service Port On Purge Line
      G04436082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Stop the engine.
      2. Disconnect the intelligent tester from the DLC3.
    7. When not using the intelligent tester:

      Conclude operation of the purge VSV.

      1. Stop the engine.
      2. Disconnect the positive (+) and negative (-) leads of the battery from the purge VSV terminals.
      3. Connect the purge VSV connector.
    8. Disconnect the vacuum gauge from the EVAP service port on the purge line.
    9. Connect a pressure gauge to the EVAP service port on the purge line.
    10. Check the pressure.
      1. Prepare a rubber hose that has an inside diameter of 15 to 18.5 mm (0.59 to 0.73 in.).
      2. Disconnect the atmospheric side hose of the pump module.
      3. Connect the prepared rubber hose to the pump module, and pinch the rubber hose with the clip to prevent air from entering into the canister passage.
        Fig 5: Pinching Rubber Hose
        G04436083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Apply pressure (13.5 to 15.5 in.Aq, 0.99 to 1.14 in.Hg) to the EVAP service port.

        Standard pressure: The gauge should still read over 7.7 to 8.8 in.Aq (0.57 to 0.65 in.Hg) for 2 minutes after the pressure is applied. 

        HINT:

        If you cannot apply pressure, the hose connecting the purge VSV, canister and fuel cap is loose or the purge VSV is open.

        Fig 6: Applying Pressure To EVAP Service Port
        G04436084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Check that the pressure drops when the fuel tank cap is removed while applying pressure.

        HINT:

        If the pressure does not drop when the fuel tank cap is removed, the hose connecting the service port and the fuel tank may be blocked.

    11. Disconnect the pressure gauge from the EVAP service port on the purge line.
  6. CHECK FUEL CUTOFF VALVE AND FILL CHECK VALVE 
    1. Disconnect the vent line hose from the fuel tank.
    2. Connect the pressure gauge to the fuel tank.
    3. Fill the fuel tank with fuel.
    4. Apply pressure of 4 kPa (41 gf/cm2 , 0.58 psi) to the vent port of the fuel tank.

      HINT:

      It is necessary to check the amount of fuel in the fuel tank. When the fuel tank is full, the float valve of the fill check valve is closed and no air can pass through.

    5. Remove the fuel cap, and check that the pressure drops.

      HINT:

      If the pressure does not drop, replace the fuel tank assembly.

    6. Reconnect the vent line hose to the fuel tank.
  7. CHECK AIR INLET LINE 
    Fig 7: Removing Fuel Cap & Checking Pressure Drops
    G04436085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the air inlet line hose from the canister.
    2. Check that air flows freely into the air inlet line.

      HINT:

      If air does not flow freely into the air inlet line, repair or replace it.

    3. Reconnect the air inlet line hose to the canister.
  8. CHECK PRESSURE SENSOR 
    1. Turn the ignition switch to the ON position.
    2. Measure the voltage between terminals AIP and E2 of the ECM connector.

      Standard voltage: 1.0 to 2.2 V 

      If the result is not as specified, inspect the ECM or harness (see INSPECTION PROCEDURE ).

      Fig 8: Identifying E8 ECM Connector
      G04436086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. CHECK VACUUM SWITCHING VALVE (for Air Injection System) 
    1. Disconnect the VSV connector.
    2. Disconnect the 2 vacuum hoses from the VSV.
      Fig 9: Identifying VSV Connector
      G04436087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Measure the resistance between the terminals.

      Standard resistance 

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      1 - 2 33 to 39 Ω at 20°C (68°F)
      1 - Body ground 1 MΩ or higher
      2 - Body ground 1 MΩ or higher

      If the resistance is not as specified, replace the VSV.

      Fig 10: Measuring Resistance Between Terminals
      G04436088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply air to the port as shown in Fig 11 .
    5. Check that air does not flow from port A.

      If the result is not as specified, replace the VSV.

      Fig 11: Checking Air Flow From Port A
      G04436089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Apply positive battery voltage to the terminals, apply air to the port, and check that air flows from the port shown in Fig 12 .

      If the result is not as specified, replace VSV.

    7. Connect the 2 vacuum hoses to the VSV.
      NOTE: Be sure to connect the vacuum hoses correctly.
    8. Connect the VSV connector.
    9. Perform the "Check Vacuum Switching Valve" procedures above on the other VSV.
      Fig 12: Checking Positive Battery Voltage To Terminals
      G04436090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. CHECK NO. 2 AIR SWITCHING VALVE 
    1. Disconnect the vacuum hose from the VSV (for air injection system).
    2. Apply vacuum of 30 kPa (306 gf/cm2 , 4.35 psi) to vacuum hose, and check that the vacuum does not decrease.

      If operation is not as specified, replace the No. 2 air switching valve.

      Fig 13: Disconnecting Vacuum Hose From VSV (For Air Injection System)
      G04436091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Release the vacuum, and check that the operation sound is emitted from the No. 2 air switching valve.

      If operation is not as specified, replace the No. 2 air switching valve.

    4. Perform the "Check No. 2 Air Switching Valve" procedures above on the other No. 2 air switching valve.
      Fig 14: Checking Air Switching Valve
      G04436092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002


(2006/01-)

  1. VISUALLY CHECK HOSES, CONNECTORS AND GASKETS 
    1. Check that there are no cracks, leaks or damage.
      NOTE:
      • Detachment or other problems with the engine oil dipstick, filler cap, PCV hose and other components 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 an engine failure or engine failure malfunctions.
      Fig 1: Checking Hoses, Connectors & Gaskets
      G04436093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the result is not as specified, replace parts as necessary.

  2. CHECK FUEL CUT OFF RPM 
    1. Start and warm up the engine.
    2. Open the throttle valve and keep the engine speed at 3,000 RPM.
    3. Use a sound scope to check for injector operating noise.
    4. Check that when the accelerator pedal is released, injector operation noise stops momentarily and then resumes. If the result is not specified, check the injector, wiring and ECM.
  3. CHECK LINE AND CONNECTORS 
    1. Visually check for loose connections, sharp bends or damage.
  4. CHECK FUEL TANK ASSEMBLY 
    1. Visually check for deformations, cracks or fuel leakage.
  5. CHECK FUEL TANK AND VENT LINE 
    Fig 2: Applying Pressure To Vent Line Of Fuel Tank
    G04436094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the vent line tube from the canister.
    2. Connect the pressure gauge to the vent line tube.
    3. Apply 4 kPa (41 kgf/cm2 , 30 mmHg) of pressure to the vent line of the fuel tank.

      HINT:

      Perform this inspection with the fuel tank less than 90% full. When the fuel tank is full, the fuel cutoff valve closes and pressure is released through the 1.5 mm orifice. As a result, when the fuel tank cap is removed, pressure does not decrease smoothly.

    4. Check that the fuel tank pressure is maintained for some time, and does not decrease immediately.

      HINT:

      If pressure decreases immediately, one of the following may be the cause:

      • The fuel tank cap is not completely tightened.
      • The fuel tank cap is damaged.
      • Air is leaking from the vent line.
      • The fuel tank is damaged.
    5. When the fuel tank cap is removed, check that pressure is released smoothly.

      HINT:

      If the pressure does not drop, replace the fuel tank assembly.

    6. Reconnect the vent line tube to the canister.
  6. CHECK AIR INLET LINE 
    1. Disconnect the air inlet line hose from the canister.
    2. Check that air flows freely into the air inlet line.

      HINT:

      If air does not flow freely into the air inlet line, repair or replace it.

    3. Reconnect the air inlet line hose to the canister.
  7. CHECK PRESSURE SENSOR 
    1. Turn the ignition switch to the ON position.
    2. Measure the voltage between terminals E5-32 (AIP) and E5-28 (E2) of the ECM connector.

      Standard voltage: 1.0 to 2.2 V 

      If the result is not as specified, inspect the ECM and harness (see INSPECTION PROCEDURE ).

      Fig 3: Identifying E5 ECM Connector
      G04436095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CHECK VACUUM SWITCHING VALVE (for Air Injection System) 
    1. Disconnect the VSV connector.
    2. Disconnect the 2 vacuum hoses from the VSV.
      Fig 4: Disconnecting VSV Connector
      G04436096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Measure the resistance between the terminals.

      Standard resistance 

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      1 - 2 26 to 30 Ω at 20°C (68°F)
      1 - Body ground 1 MΩ or higher
      2 - Body ground 1 MΩ or higher

      If the resistance is not as specified, replace the VSV.

      Fig 5: Measuring Resistance Between Terminals
      G04436097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply air to the port shown in Fig 6 .
    5. Check that air does not flow from port A.

      If the result is not as specified, replace the VSV.

      Fig 6: Checking Air Flow From Port A
      G04436098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Apply positive battery voltage to the terminals, apply air to the port, and check that air flows from the port shown in Fig 7 .

      If the result is not as specified, replace the VSV.

    7. Connect the 2 vacuum hoses to the VSV.
      NOTE: Be sure to connect the vacuum hoses correctly.
    8. Connect the VSV connector.
    9. Perform all procedures above on the other VSV.
      Fig 7: Applying Positive Battery Voltage To Terminals
      G04436099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. CHECK NO. 2 AIR SWITCHING VALVE 
    1. Disconnect the vacuum hose from the VSV (for air injection system).
    2. Apply vacuum of 30 kPa (306 kgf/cm2 , 4.35 psi) to vacuum hose, and check that the vacuum does not decrease.

      If the operation is not as specified, replace the No. 2 air switching valve.

      Fig 8: Disconnecting Vacuum Hose From VSV (For Air Injection System)
      G04436100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Release the vacuum, and check that the operation sound is emitted from the No. 2 air switching valve.

      If the operation is not as specified, replace the No. 2 air switching valve.

    4. Perform all procedures above on the other No. 2 air switching valve.
      Fig 9: Checking Air Switching Valve
      G04436101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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