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Home >> Toyota >> 2006 >> Highlander Base, 2.4 D, AWD >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System (2AZ-FE) (Except Hybrid) >> SFI System >> EVAP System >> Inspection Procedure

Inspection Procedure

NOTE: The intelligent tester is required to conduct the following diagnostic troubleshooting procedure.

HINT:

  1. 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 intelligent tester to the DLC3.
    5. Turn the ignition switch ON and press the intelligent tester switch ON.
    6. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT 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.
      Fig 1: DTC Malfunction Areas Chart
      G04424126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  2. PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
    NOTE:
    • In the EVAP SYSTEM CHECK (AUTO OPERATION), the series of 5 EVAP SYSTEM CHECK steps are performed automatically. It takes a maximum of approximately 18 minutes.
    • Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut-off valve may be closed and making the leak check of the fuel tank unavailable.
    • 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 EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F).
    1. Clear the DTCs (See DTC CHECK / CLEAR ).
    2. On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION.
    3. After the EVAP SYSTEM CHECK is completed, check for pending DTCs by selecting the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES.

      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.

  3. PERFORM EVAP SYSTEM CHECK (MANUAL OPERATION)
    Fig 2: EVAP Pressure System Graph (Manual Operation)
    G04424127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • In the EVAP SYSTEM CHECK (MANUAL OPERATION), the series of 5 EVAP SYSTEM CHECK steps are performed manually.
    • Do not perform the EVAP 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 unavailable.
    • 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 EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F).
    1. Clear the DTCs (See DTC CHECK / CLEAR ).
    2. On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / MANUAL OPERATION.
  4. PERFORM EVAP SYSTEM CHECK (STEP 1/5)
    Fig 3: EVAP Pressure System Graph (Step 1/5)
    G04424128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the EVAP pressure in step 1/5.

      Result

      TEST RESULTS REFERENCE

      DTC No. (1) 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 Pressure sensor noisy B
      (1) The DTCs relating to the EVAP system are displayed on the intelligent tester when checking.

    B: Go to step  30

    A: GO TO NEXT STEP

  5. PERFORM EVAP SYSTEM CHECK (STEP 1/5 TO 2/5)
    Fig 4: EVAP Pressure System (Step 1/5 To 2/5)
    G04424129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the EVAP pressure in step 1/5 and 2/5.

      Result

      TEST RESULTS REFERENCE

      DTC No.(1) Test Results Suspected Trouble Areas Proceed To
      - Virtually no variation in EVAP pressure during step 1/5. Then decreases to 0.02 inch leak pressure standard* Not yet determined A
      P2402 Small difference between EVAP pressures during steps 1/5 and 2/5 Vacuum pump stuck ON B
      (1) The DTCs related to the EVAP system are displayed on the intelligent tester when checking.

      HINT:

      The first 0.02 inch leak pressure standard is the value determined in step 2/5.

    B: Go to step  23

    A: GO TO NEXT STEP

  6. PERFORM EVAP SYSTEM CHECK (STEP 2/5)
    Fig 5: EVAP Pressure System Graph (Step 2/5)
    G04424130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    Make a note of the pressures checked in the procedure "A" and "B" below.

    1. Check the EVAP pressure 4 seconds after the vacuum pump is activated* (Procedure "A").
    2. Check the EVAP pressure again when it has stabilized. This pressure is the 0.02 inch leak pressure standard.

      *: The vacuum pump begins to operate as step 1/5 is proceeded to step 2/5 (Procedure "B").

      Result

      TEST RESULTS REFERENCE

      DTC No. (1) Test Results Suspected Trouble Areas Proceed To
      - EVAP pressure in procedure "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 procedure "B" -1.06 kPa (-7.95 mmHg) or more
      • 0.02 inch orifice high-flow
      • Vacuum pump stuck OFF
      B
      P043E EVAP pressure in procedure "B" below -4.85 kPa (-36.38 mmHg) 0.02 inch orifice clogged C
      P2419 EVAP pressure in procedure "A" more than -1.06 kPa (-7.95 mmHg) Vent valve stuck closed D
      (1) The DTCs related to the EVAP system are displayed on the intelligent tester when checking.

    B: Go to step  11

    C: Go to step  30

    D: Go to step  19

    A: GO TO NEXT STEP

  7. PERFORM EVAP SYSTEM CHECK (STEP 2/5 TO 3/5)
    Fig 6: EVAP Pressure System Graph (Step 2/5 To 3/5)
    G04424131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the EVAP pressure in step 3/5.

      Result

      TEST RESULTS REFERENCE

      DTC No. (1) 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 Pressure sensor malfunction (stuck) C
      (1) The DTCs related to the EVAP system are displayed on the intelligent tester when checking.

    B: Go to step  20

    C: Go to step  30

    A: GO TO NEXT STEP

  8. PERFORM EVAP SYSTEM CHECK (STEP 3/5)
    Fig 7: EVAP Pressure System Graph (Step 3/5)
    G04424132Courtesy 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 15 minutes.

  9. PERFORM EVAP SYSTEM CHECK (STEP 4/5)
    Fig 8: EVAP Pressure System Graph (Step 4/5)
    G04424133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the EVAP pressure in step 4/5.

      Result

      TEST RESULTS REFERENCE

      DTC No. (1) 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 throttle body 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
      (1) The DTCs related to the EVAP system are displayed on an intelligent tester when checking.

    B: Go to step  15

    C: Go to step  12

    A: GO TO NEXT STEP

  10. PERFORM EVAP SYSTEM CHECK (STEP 5/5)
    Fig 9: EVAP Pressure System Graph (Step 5/5)
    G04424134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the EVAP pressure in step 5/5.
    2. Compare the EVAP pressure in step 3/5 and the second 0.02 inch leak pressure standard (step 5/5).

      Result

      TEST RESULTS REFERENCE

      DTC No.(1) Test Results Suspected Trouble Areas Proceed To
      - EVAP pressure (step 3/5) lower than the second 0.02 inch leak pressure standard (step 5/5) Not yet determined (No leafage from EVAP system) A
      P0441 and P0455 EVAP pressure (step 3/5) higher than [second 0.02 inch leak pressure standard (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 pressure standard (step 5/5) EVAP small leak C
      (1) The DTCs related to the EVAP system are displayed on the intelligent tester when checking.

    A: Go to step  36

    B: Go to step  12

  11. PERFORM EVAP SYSTEM CHECK (STEP 3/5)
    Fig 10: EVAP Pressure System Graph (Step 3/5)
    G04424135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the EVAP pressure in step 3/5.

      Result

      TEST RESULTS REFERENCE

      DTC No.(1) Test Results Suspected Trouble Areas Proceed To
      P043F and P2401 EVAP pressure less than [0.02 inch leak pressure standard x 0.2] 0.02 inch orifice high-flow A
      P043F and P2401 EVAP pressure more than [0.02 inch leak pressure standard x 0.2] Vacuum pump stuck OFF B
      (1) The DTCs related to the EVAP system are displayed on the intelligent tester when checking.

      HINT:

      The first 0.02 inch leak pressure standard is the value determined in step 2/5.

    A: Go to step  30

    B: Go to step  23

  12. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (PURGE VSV)
    1. On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV.
    2. Disconnect the hose (connected to the canister) from the purge VSV.
    3. Start the engine.
    4. On the tester, turn off the purge VSV (EVAP VSV: OFF).
    5. Use your finger to confirm that the purge VSV has no suction.
    6. Using the tester, turn on the purge VSV (EVAP VSV: ON).
    7. Use your finger to confirm that the purge VSV has suction.
      Fig 11: Disconnecting Hose From Purge VSV
      G04424136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result

      TEST RESULTS REFERENCE

      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 EVAP hose between purge VSV and throttle body
      C
    8. Reconnect the hose.

    B: Go to step  14

    C: Go to step  15

    A: GO TO NEXT STEP

  13. CHECK FUEL TANK CAP ASSEMBLY
    1. Check that the fuel tank cap is correctly installed.
    2. Confirm that the fuel tank cap is tightened until a few click sounds are heard.

      HINT:

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

      1. Remove the fuel tank cap and install it onto a fuel tank cap adaptor.
      2. Connect an EVAP tester pump hose to the adaptor, and pressurize to 3.2 to 3.7 kPa (24 to 28 mmHg) using an EVAP tester pump.
      3. Seal the adaptor and wait for 2 minutes.
      4. Check the pressure. If the pressure is 2 kPa (15 mmHg) or more, the fuel tank cap is normal.
      5. Reinstall the fuel tank cap.

        Result

        TEST RESULTS REFERENCE

        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

    A: Go to step  29

    B: Go to step  27

    C: Go to step  28

  14. INSPECT VACUUM SWITCHING VALVE ASSEMBLY NO.1
    1. Turn the ignition switch to OFF.
    2. Disconnect the purge VSV connector.
    3. Disconnect the hose (connected to the canister) from the purge VSV.
    4. Start the engine.
    5. Use your finger to confirm that the purge VSV has no suction.

      Result

      TEST RESULTS REFERENCE

      Test Results Suspected Trouble Areas Proceed To
      No suction ECM A
      Suction applied Purge VSV B
    6. Reconnect the purge VSV connector.
    7. Reconnect the hose.

    A: Go to step  35

    B: Go to step  31

    Fig 12: Connecting Hose To Canister On Purge VSV
    G04424137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. CHECK EVAP HOSE (PURGE VSV - THROTTLE BODY)
    1. Disconnect the hose (connected to the throttle body) from the purge VSV.
    2. Start the engine.
    3. Use your finger to confirm that the hose has suction.

      Result

      TEST RESULTS REFERENCE

      Test Results Suspected Trouble Areas Proceed To
      Suction applied EVAP hose between purge VSV and throttle body normal A
      No suction
      • Throttle body
      • EVAP hose between purge VSV and throttle body
      B
    4. Reconnect the hose.

    B: Go to step  26

    Fig 13: Disconnecting Hose From Purge VSV
    G04424138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    A: GO TO NEXT STEP

  16. INSPECT VACUUM SWITCHING VALVE ASSEMBLY NO.1 (PURGE VSV)
    1. Remove the purge VSV.
    2. Apply battery voltage to the terminals of the purge VSV.
    3. Using an air gun, confirm that air flows from port A to port B.

      Result

      TEST RESULTS REFERENCE

      Test Result Suspected Trouble Area Proceed to
      Air flowed Purge VSV normal A
      No air flow Purge VSV B
    4. Install the purge VSV.

    B: Go to step  31

    Fig 14: Checking Vacuum Switch Valve To Terminals Of Purge VSV
    G04424139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    A: GO TO NEXT STEP

  17. CHECK HARNESS AND CONNECTOR (POWER SOURCE OF PURGE VSV)
    1. Disconnect the V4 Purge VSV connector.
    2. Turn the ignition switch ON.
    3. Measure the voltage between terminal 1 of the V4 connector and the body ground.

      Result

      TEST RESULTS REFERENCE

      Test Results Suspected Trouble Areas Proceed To
      Between 11 V and 14 V Normal A
      Other than result above Wire harness or connectors between purge VSV and ECM B
    4. Reconnect the purge VSV connector.

    B: Go to step  32

    Fig 15: Identifying V4 Purge VSV Connector
    G04424140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    A: GO TO NEXT STEP

  18. CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM)
    1. Disconnect the E7 ECM connector and the V4 purge VSV connector.
    2. Check the resistance.

      Standard resistance

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      E7-34 (PRG) - V1-1 Below 1 Ω
      E7-34 (PRG) - Body ground 10 kΩ or higher
      V4-2 - Body ground 10 kΩ or higher
    3. Reconnect the purge VSV connector.
    4. Reconnect the ECM connector.

    OK: Go to step  35

    NG: Go to step  32

    Fig 16: Disconnecting E7 ECM Connector
    G04424141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FOR VENT VALVE)
    1. Turn the ignition switch to ON.
    2. On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VENT VALVE (ALONE).
    3. Measure the voltage between terminal VPMP of the ECM connector and the body ground when the vent valve is turned ON (close) and OFF (vent) using the tester.

      Result

      TEST RESULTS REFERENCE

      Test Results Suspected Trouble Areas Proceed To
      Between 9 V and 14 V when OFF
      Below 3 V when ON
      Vent valve A
      Below 3 V when OFF and ON ECM B

    A: Go to step  22

    B: Go to step  35

    Fig 17: Identifying ECM Connector
    G04424142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FOR VENT VALVE)
    1. Turn the ignition switch to ON.
    2. On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VENT VALVE (ALONE).
    3. Measure the voltage between terminal VPMP of the ECM connector and the body ground when the vent valve is turned ON (close) and OFF (vent) using the tester.

      Result

      TEST RESULTS REFERENCE

      Test Results Suspected Trouble Areas Proceed To
      Between 3 V when OFF and ON Power source of vent valve A
      Between 9 V and 14 V when OFF
      Below 3 V when ON
      Vent valve B
      Between 9 V and 14 V when OFF and ON ECM C

    B: Go to step  22

    C: Go to step  35

    Fig 18: Locating ECM Connector
    G04424143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    A: GO TO NEXT STEP

  21. INSPECT PUMP MODULE (POWER SOURCE FOR VENT VALVE)
    1. Turn the ignition switch OFF.
    2. Disconnect the C17 canister connector.
    3. Turn the ignition switch to ON.
    4. Measure the voltage between terminal 9 of the canister connector and the body ground.

      Result

      TEST RESULTS REFERENCE

      Test Results Suspected Trouble Areas Proceed To
      Between 9 V and 14 V Normal A
      Between 0 V and 3 V Power source wire harness of vent valve B
    5. Reconnect the canister connector.

    B: Go to step  32

    Fig 19: Identifying C17 Canister Connector
    G04424144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    A: GO TO NEXT STEP

  22. INSPECT PUMP MODULE (VENT VALVE OPERATION)
    1. Turn the ignition switch to OFF.
    2. Disconnect the canister connector.
    3. Apply the battery voltage to terminals 9 and 8 of the pump module.
    4. Touch the pump module to confirm the vent valve operation.

      Result

      TEST RESULTS REFERENCE

      Test Results Suspected Trouble Areas Proceed To
      Operating Wire harness between vent valve and ECM A
      Not operating Vent valve B
    5. Reconnect the canister connector.

    A: Go to step  32

    B: Go to step  30

    Fig 20: Disconnecting Canister Connector
    G04424145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FOR PUMP MODULE (VACUUM PUMP))
    1. On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP (ALONE).
    2. Measure the voltage between MPMP terminal of ECM connector and the body ground when the vacuum pump is turned ON and OFF using the tester.

      Result

      TEST RESULTS REFERENCE

      Test Results Suspected Trouble Areas Proceed To
      Between 0 V and 3 V when OFF
      Between 9 V and 14 V when ON
      ECM normal A
      Between 9 V and 14 V when OFF
      Between 0 V and 3 V when ON
      ECM B

    B: Go to step  35

    Fig 21: Identifying Voltage Between MPMP Terminal Of ECM Connector
    G04424146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    A: GO TO NEXT STEP

  24. CHECK HARNESS AND CONNECTOR (PUMP MODULE - ECM)
    1. Turn the ignition switch OFF.
    2. Disconnect the C17 canister connector.
    3. Turn the ignition switch to ON.
    4. On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP (ALONE).
    5. Turn the vacuum pump ON.
    6. Measure the voltage between terminal 1 of the canister connector and the body ground.

      Result

      TEST RESULTS REFERENCE

      Test Result Suspected Trouble Area Proceed to
      Between 9 V and 14 V Normal A
      Between 0 V and 3 V Wire harness between ECM and vacuum pump B
    7. Reconnect the canister connector.

    B: Go to step  32

    Fig 22: Locating C17 Canister Connector
    G04424147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    A: GO TO NEXT STEP

  25. CHECK HARNESS AND CONNECTOR (PUMP MODULE - GROUND)
    1. Disconnect the C17 canister connector.
    2. Turn the engine switch to OFF.
    3. Check the resistance between terminal 6 of the canister connector and the body ground.

      Result

      TEST RESULTS REFERENCE

      Test Result Suspected Trouble Area Proceed to
      Below 1 Ω Vacuum Pump A
      10 kΩ or higher Wire harness between vacuum pump and body ground B
    4. Reconnect the canister connector.

    A: Go to step  30

    B: Go to step  32

    Fig 23: Identifying C17 Canister Connector Terminal
    G04424148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSPECT THROTTLE BODY ASSEMBLY
    1. Stop the engine.
    2. Disconnect the EVAP hose from the throttle body.
    3. Start the engine.
    4. Use your finger to confirm that the port of the throttle body has suction.

      Result

      TEST RESULTS REFERENCE

      Test Results Suspected Trouble Areas Proceed To
      Suction applied EVAP hose between throttle body and purge VSV A
      No suction Throttle body B
    5. Reconnect the EVAP hose.

    A: Go to step  33

    B: Go to step  34

  27. 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 tank cap that meets OEM specifications, and tighten it until a few click sounds are heard.

    NEXT: Go to step  37

  28. REPLACE FUEL TANK CAP ASSEMBLY

    HINT:

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

    NEXT: Go to step  37

  29. REPAIR EVAP LEAK PART
    1. Reinstall the fuel cap.
    2. Remove the exhaust tail pipe.
    3. Remove the heat insulator under the canister.
    4. Pinch the atmospheric side hose of the pump module with the clip to close the canister's passage to air.
    5. Connect the pressure gauge (SST) to the service port (green cap near the air cleaner box).
    6. Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28 mmHg).
      NOTE: More than 35 mmHg of pressure will damage the EVAP system. Pay attention to the pressure.
    7. Apply soapy water to the piping and connecting parts of the EVAP system. Look for the area where bubbles appear. This area cause leaks.

      HINT:

      • If the system has leaks, a whistling sound will be heard.
      • Disconnect the hose between canister and fuel tank from the canister. Close the canister on the area where the hose was connected and perform an inspection. The fuel tank can be eliminated from the suspected areas for leak checks.
    8. Repair or replace the leak point.

    NEXT: Go to step  37

    Fig 24: Connecting Pressure Gauge (SST) To Service Port
    G04424149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REPLACE CHARCOAL CANISTER ASSEMBLY

    NEXT: Go to step  37

  31. REPLACE VACUUM SWITCHING VALVE ASSEMBLY NO.1 (PURGE VSV)
    1. Disconnect the connector and hoses from the purge VSV.
    2. Remove the purge VSV.
    3. Install a new purge VSV.
    4. Reconnect the connector and hoses.

    NEXT: Go to step  37

    Fig 25: Disconnecting Hoses From Purge VSV
    G04424150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REPAIR OR REPLACE HARNESS AND CONNECTOR
    1. In case that the exhaust tail pipe is removed, go to the next step before installing it.

    NEXT: Go to step  37

  33. REPLACE EVAP HOSE (THROTTLE BODY - PURGE VSV)

    NEXT: Go to step  37

  34. INSPECT THROTTLE BODY ASSEMBLY
    1. Remove the throttle body (See REMOVAL ).
    2. Check that there is no clog in the EVAP purge port of the throttle body. If necessary, replace the throttle body.

    NEXT: Go to step  37

  35. REPLACE ECM

    NEXT: Go to step  37

  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.
  37. PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
    NOTE:
    • In the EVAP SYSTEM CHECK (AUTO OPERATION), the series of 5 EVAP SYSTEM CHECK steps are performed automatically. It takes a maximum of approximately 18 minutes.
    • Do not perform the EVAP 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 unavailable.
    • 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 EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F).
    1. Clear the DTCs (See DTC CHECK / CLEAR ).
    2. On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION.
    3. After the SYSTEM CHECK is completed, check for pending DTCs by selecting the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES.

      HINT:

      If no pending DTC is found, the repair has been successfully completed.

    NEXT: COMPLETED