Inspection Procedure

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

HINT:

Using Techstream monitor results enables the EVAP (Evaporative Emission) system to be confirmed.
Read freeze frame data using the Techstream. Freeze frame data records the engine condition when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred.

CONFIRM DTC
1. Turn the ignition switch off and wait for 10 seconds.
2. Turn the ignition switch to ON.
3. Turn the ignition switch off and wait for 10 seconds.
4. Connect the Techstream to the DLC3.
5. Turn the ignition switch to ON.
6. Turn the Techstream ON.
7. Enter the following menus: Powertrain / Engine / Trouble Codes.
8. Confirm DTCs and freeze frame data.
  If any EVAP system DTCs are output, the malfunctioning area can be determined using the table below.
  
  NOTE: If the reference pressure difference between the first and second checks is greater than the specification, all the DTCs relating to the reference pressure (P043E, P043F, P2401, P2402 and P2419) are stored.
  
  Fig 1: DTC Malfunctioning Area Chart
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
NOTE:
- The Evaporative System Check (Automatic Mode) consists of 5 steps performed automatically by the Techstream. It takes a maximum of approximately 18 minutes.
- Do not perform the Evaporative System Check when the fuel tank is more than 90% full because the cut-off valve may be closed. If the cut-off valve is closed, the fuel tank leak check is not possible.
- Do not run the engine during this operation.
- 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 Evaporative System Check, keep the temperature below 35°C (95°F).
1. Clear DTCs (See DTC CHECK / CLEAR ).
2. Enter the following menus: Powertrain / Engine / Utility / Evaporative System Check / Automatic Mode.
3. After the Evaporative System Check is completed, check for pending DTCs by entering the following menus: Powertrain / Engine / Trouble Codes / Pending.
  HINT:
  
  If no pending DTCs are displayed, perform the Monitor Confirmation (see "Diagnostic Help" menu). After this confirmation, check for pending DTCs. If no DTCs are displayed, the EVAP system is normal.
PERFORM EVAP SYSTEM CHECK (MANUAL OPERATION)

Fig 2: EVAP System Pressure Graph (Manual Operation)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- In the Evaporative System Check (Manual Mode), perform the series of 5 Evaporative System Check steps manually using the Techstream.
- Do not perform the Evaporative System Check when the fuel tank is more than 90% full because the cut-off valve may be closed. If the cut-off valve is closed, the fuel tank leak check is not possible.
- Do not run the engine during this operation.
- 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 Evaporative System Check, keep the temperature below 35°C (95°F).
1. Clear DTCs (See DTC CHECK / CLEAR ).
2. Enter the following menus: Powertrain / Engine / Utility / Evaporative System Check / Manual Mode.

PERFORM EVAP SYSTEM CHECK (STEP 1/5)

Fig 3: EVAP System Pressure Graph (Step 1/5)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 1/5

Result

RESULT CHART

DTC No.⁽¹⁾

Result

Suspected Trouble Area

Proceed to

Virtually no variation in EVAP pressure

Not yet determined

P0451

EVAP pressure fluctuates by +/-0.3 kPa-g (+/-2.25 mmHg-g) or more

Canister pressure sensor noise

⁽¹⁾	These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "Confirm DTC" procedures above.

B: Go to step 29

A: Go to Next Step.

PERFORM EVAP SYSTEM CHECK (STEP 1/5 TO 2/5)

Fig 4: EVAP System Pressure Graph (Step 1/5 To 2/5)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 1/5 and 2/5.

Result

RESULT CHART

DTC No.⁽¹⁾

Result

Suspected Trouble Area

Proceed to

Virtually no variation in EVAP pressure during step 1/5. Then decreases to reference pressure

Not yet determined

P2402

Small difference between EVAP pressures during steps 1/5 and 2/5

Leak detection pump stuck ON

⁽¹⁾	These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "Confirm DTC" procedures above.

HINT:

The first reference pressure is the value determined in step 2/5.

B: Go to step 22

A: Go to Next Step.

PERFORM EVAP SYSTEM CHECK (STEP 2/5)

Fig 5: EVAP System Pressure Graph (Step 2/5)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Make a note of the pressures checked in steps (a) and (b) below.

Check the EVAP pressure 4 seconds after the leak detection pump is activated*.
*: The leak detection pump begins to operate as step 1/5 finishes and step 2/5 starts.

Check the EVAP pressure again when it has stabilized. This pressure is the reference pressure.

Result

RESULT CHART

DTC No.⁽¹⁾

Result

Suspected Trouble Area

Proceed to

EVAP pressure in step (b) between -4.85 kPa-g and -1.057 kPa-g (-36.4 mmHg-g and -7.93 mmHg-g)

Not yet determined

P043F AND P2401

EVAP PRESSURE IN STEP (B) -1.057 KPA-G (-7.93 MMHG-G) OR MORE

Reference orifice high-flow
Leak detection pump stuck OFF

P043E

EVAP pressure in step (b) below -4.85 kPa-g (-36.4 mmHg-g)

Reference orifice clogged

P2419

EVAP pressure in step (a) more than -1.057 kPa-g (-7.93 mmHg-g)

Vent valve stuck closed

⁽¹⁾	These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "Confirm DTC" procedures above.

B: Go to step 11

C: Go to step 29

D: Go to step 20

A: Go to Next Step.

PERFORM EVAP SYSTEM CHECK (STEP 2/5 TO 3/5)

Fig 6: EVAP System Pressure Graph (Step 2/5 To 3/5)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure increase in step 3/5.

Result

RESULT CHART

DTC No.⁽¹⁾

Result

Suspected Trouble Area

Proceed to

EVAP pressure increases by 0.3 kPa-g (2.25 mmHg-g) or more within 10 seconds of proceeding from step 2/5 to step 3/5

Not yet determined

P2420

No variation in EVAP pressure despite proceeding from step 2/5 to step 3/5

Vent valve stuck open (vent)

P0451

No variation in EVAP pressure during steps 1/5 through 3/5

Canister pressure sensor output value stuck

⁽¹⁾	These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "Confirm DTC" procedures above.

B: Go to step 19

C: Go to step 29

A: Go to Next Step.

PERFORM EVAP SYSTEM CHECK (STEP 3/5)

Fig 7: EVAP System Pressure Graph (Step 3/5)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Wait until the EVAP pressure change is less than 0.1 kPa-g (0.75 mmHg-g) 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.

PERFORM EVAP SYSTEM CHECK (STEP 4/5)

Fig 8: EVAP System Pressure Graph (Step 4/5)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 4/5.

Result

RESULT CHART

DTC No.⁽¹⁾

Result

Suspected Trouble Area

Proceed to

EVAP pressure increases by 0.3 kPa-g (2.25 mmHg-g) or more within 10 seconds of proceeding from step 3/5 to step 4/5

Not yet determined

P0441

EVAP pressure increases by 0.3 kPa-g (2.25 mmHg-g) or more within 10 seconds of proceeding from step 3/5 to step 4/5

Problems in purge line between purge VSV and intake manifold

P0441

Variation in EVAP pressure less than 0.3 kPa-g (2.25 mmHg-g) for 10 seconds, after proceeding from step 3/5 to step 4/5

Purge VSV stuck closed

⁽¹⁾	These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "Confirm DTC" procedures above.

B: Go to step 15

C: Go to step 12

A: Go to Next Step.

PERFORM EVAP SYSTEM CHECK (STEP 5/5)

Fig 9: EVAP System Pressure Graph (Step 5/5)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 5/5.

Compare the EVAP pressure in step 3/5 and the second reference pressure (step 5/5).

Result

RESULT CHART

DTC No.⁽¹⁾

Result

Suspected Trouble Area

Proceed to

EVAP pressure (step 3/5) lower than second reference pressure (step 5/5)

Not yet determined (no leak from EVAP system)

P0441 and P0455

EVAP pressure (step 3/5) higher than [second reference pressure (step 5/5) x 0.2]

Purge VSV stuck open
EVAP gross leak

P0456

EVAP pressure (step 3/5) higher than second reference pressure (step 5/5)

EVAP small leak

⁽¹⁾	These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "Confirm DTC" procedures above.

A: Go to step 35

B: Go to step 12

PERFORM EVAP SYSTEM CHECK (STEP 3/5)

Fig 10: EVAP System Pressure Graph (Step 3/5)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 3/5.

Result

RESULT CHART

DTC No.⁽¹⁾

Result

Suspected Trouble Area

Proceed to

P043F

EVAP pressure less than [reference pressure] measured at 2/5

Reference orifice high-flow

P2401

EVAP pressure almost same as [reference pressure] measured at 2/5

Leak detection pump stuck OFF

⁽¹⁾	These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "Confirm DTC" procedures above.

HINT:

The first reference pressure is the value determined in step 2/5.

A: Go to step 29

B: Go to step 22

PERFORM ACTIVE TEST USING TECHSTREAM (PURGE VSV)

Enter the following menus using the Techstream: Powertrain / Engine / Active Test / Activate the VSV for EVAP Control.
Disconnect the hose (connected to the canister) from the purge VSV.
Start the engine.
Using the Techstream, turn off the purge VSV (Activate the VSV for EVAP Control: OFF).
Use your finger to confirm that the purge VSV has no suction.
Using the Techstream, turn on the purge VSV (Activate the VSV for EVAP Control: ON).

Use your finger to confirm that the purge VSV has suction.

Fig 11: Disconnecting Hose (Connected To Canister) From Purge VSV

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT CHART

Result	Suspected Trouble Area	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 purge line between purge VSV and intake manifold	C

B: Go to step 14

C: Go to step 15

A: Go to Next Step.

CHECK FUEL TANK CAP ASSEMBLY

Check that the fuel tank cap is correctly installed and confirm the fuel tank cap meets OEM specifications.

Tighten the fuel tank cap until a few click sounds are heard.

HINT:

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

Remove the fuel tank cap and install it onto a fuel tank cap adapter.
Connect an EVAP tester pump hose to the adapter, and pressurize the cap to 3.2 to 3.7 kPa (24 to 28 mmHg) using the tester pump.
Seal the adapter and wait for 2 minutes.

Check the pressure. If the pressure is 2 kPa (15 mmHg) or more, the fuel tank cap is normal.

Result

RESULT CHART

Result	Suspected Trouble Area	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
Defective fuel tank cap	-	B
No fuel tank cap	-	C

A: Go to step 28

B: Go to step 26

C: Go to step 27

INSPECT PURGE VSV

Turn the ignition switch off.
Disconnect the purge VSV connector.
Disconnect the hose (connected to the canister) from the purge VSV.
Start the engine.

Use your finger to confirm that the purge VSV has no suction.

Fig 12: Disconnecting Hose (Connected To Canister) From Purge VSV

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT CHART

Result	Suspected Trouble Area	Proceed to
No suction	ECM	A
Suction applied	Purge VSV	B

A: Go to step 34

B: Go to step 30

CHECK PURGE LINE (PURGE VSV - INTAKE MANIFOLD)

Disconnect the hose (connected to the intake manifold) from the purge VSV.
Start the engine.

Use your finger to confirm that the hose has suction.

Fig 13: Disconnecting Hose (Connected To Intake Manifold) From Purge VSV

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT CHART

Result	Suspected Trouble Area	Proceed to
Suction applied	Purge line between purge VSV and intake manifold normal	A
No suction	Intake manifold port Purge line between purge VSV and intake manifold	B

B: Go to step 25

A: Go to Next Step.

INSPECT PURGE VSV

Remove the purge VSV.
Apply the battery voltage to the terminals of the purge VSV.

Using an air gun, confirm that air flows from port A to port B.

Fig 14: Applying Battery Voltage To Terminals Of Purge VSV

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT CHART

Result	Suspected Trouble Area	Proceed to
Air flows	-	A
No air flow	Purge VSV	B

B: Go to step 30

A: Go to Next Step.

CHECK HARNESS AND CONNECTOR (POWER SOURCE OF PURGE VSV)

Disconnect the purge VSV connector.
Turn the ignition switch to ON.

Measure the voltage between terminal 2 of the purge VSV connector and the body ground.

Fig 15: Identifying Purge VSV Connector Terminals

Result

RESULT CHART

Result	Suspected Trouble Area	Proceed to
11 to 14 V	Normal	A
Other than result above	Wire harness or connectors between purge VSV and ECM	B

B: Go to step 31

A: Go to Next Step.

CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM)

Disconnect the ECM connector and the purge VSV connectors.

Measure the resistance according to the value(s) in the table below.

Standard Resistance

RESISTANCE SPECIFICATION

Tester Connection	Condition	Specified Condition
D56-63(PRG)-D16-1	Always	Below 1 Ω
D56-63 (PRG) - Body ground	Always	10 kΩ or higher
D16-2 - Body ground	Always	10 kΩ or higher

OK: Go to step 34

NG: Go to step 31

Fig 16: Identifying ECM Connector And Purge VSV Connectors

INSPECT CANISTER PUMP MODULE (POWER SOURCE FOR VENT VALVE)

Turn the ignition switch off.
Disconnect the canister pump module connector.
Turn the ignition switch to ON.

Measure the voltage between VLVB terminal of the canister pump module connector and the body ground.

Fig 17: Identifying Canister Pump Module Connector Terminal

Result

RESULT CHART

Result	Suspected Trouble Area	Proceed to
11 to 14 V	Wire harness between vent valve and ECM Vent valve ECM	A
Below 3 V	Power source wire harness of vent valve	B

B: Go to step 31

A: Go to Next Step.

INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION)

Turn the ignition switch off.
Disconnect the canister pump module connector.
Apply the battery voltage to 9 (VLVB) and 8 (VGND) terminals of the canister pump module.

Touch the canister pump module to confirm the vent valve operation.

Fig 18: Inspecting Canister Pump Module (Vent Valve Operation)

Result

RESULT CHART

Result	Suspected Trouble Area	Proceed to
Operating	Wire harness between vent valve and ECM ECM	A
Not operating	Vent valve	B

B: Go to step 29

A: Go to Next Step.

CHECK HARNESS AND CONNECTOR (ECM - CANISTER PUMP MODULE)

Disconnect the ECM connector.
Disconnect the canister pump module connector.

Fig 19: Identifying ECM And Canister Pump Module Connector Terminals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Measure the resistance between VPMP terminal of the ECM connector and VGND terminal of the canister pump module connector.

Result

RESULT CHART

Result	Suspected Trouble Area	Proceed to
Below 1 Ω	ECM	A
10 kΩ or higher	Wire harness between ECM and canister pump module	B

A: Go to step 34

B: Go to step 31

PERFORM ACTIVE TEST USING TECHSTREAM (VACUUM PUMP [ALONE])

Turn the ignition switch off.
Disconnect the canister pump module connector.
Turn the ignition switch to ON.
Turn the Techstream ON.
Enter the following menus: Powertrain / Engine / Active Test / Activate the Vacuum Pump.

Measure the voltage between MTRB terminal 1 of the canister pump module connector and the body ground when the leak detection pump is turned ON and OFF using the Techstream.

Fig 20: Identifying Canister Pump Module Connector Terminal

Result

RESULT CHART

Result	Suspected Trouble Area	Proceed to
Below 3 V when OFF 9 to 14 V when ON	Wire harness between leak detection pump and body ground Leak detection pump	A
Below 3 V when OFF and ON	Wire harness between leak detection pump and ECM ECM	B

B: Go to step 24

A: Go to Next Step.

CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - BODY GROUND)

Turn the ignition switch off.
Disconnect the canister pump module connector.

Check the resistance between the MGND terminal of the canister pump module connector and the body ground.

Fig 21: Identifying Canister Pump Module Connector Terminal

Result

RESULT CHART

Result	Suspected Trouble Area	Proceed to
Below 1 Ω	Leak detection pump	A
10 kΩ or higher	Wire harness between canister pump module and body ground	B

A: Go to step 29

B: Go to step 31

CHECK HARNESS AND CONNECTOR (ECM - CANISTER PUMP MODULE)

Turn the ignition switch off.
Disconnect the canister pump module connector.
Disconnect the ECM connector.

Measure the resistance between MPMP terminal of the ECM connector and MTRB terminal of the canister pump module connector.

Fig 22: Identifying ECM And Canister Pump Module Connector Terminals

Result

RESULT CHART

Result	Suspected Trouble Area	Proceed to
Below 1 Ω	ECM	A
10 kΩ or higher	Wire harness between ECM and canister pump module	B

A: Go to step 34

B: Go to step 31

INSPECT INTAKE MANIFOLD (EVAP PURGE PORT)

Stop the engine.
Disconnect the purge line from the intake manifold.
Start the engine.

Use your finger to confirm that the port of the intake manifold has suction.

Result

RESULT CHART

Result	Suspected Trouble Area	Proceed to
Suction applied	Purge line between intake manifold and purge VSV	A
No suction	Intake manifold	B

Reconnect the purge line.

A: Go to step 32

B: Go to step 33

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 install it until a few click sounds are heard.
NEXT: Go to step 36
REPLACE FUEL TANK CAP
HINT:

When replacing the fuel cap, use a fuel cap that meets OEM specifications, and install it until a few click sounds are heard.

NEXT: Go to step 36
LOCATE EVAP LEAK PART

Fig 23: Connecting EVAP Tester To Canister Pump Module With Adapter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Disconnect the vent hose.
2. Connect an EVAP tester to the canister pump module with the adapter.
3. Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28 mmHg).
4. Apply soapy water to the piping and connecting parts of the EVAP system.
5. Look for areas where bubbles appear. This indicates the leak point.
6. Repair or replace the leak point.
  HINT:
  
  Disconnect the hose between the canister and the fuel tank from the canister. Block the canister side and conduct an inspection. In this way, the fuel tank can be excluded as an area suspected of causing fuel leaks.
NEXT: Go to step 36
REPLACE CANISTER ASSEMBLY
1. Replace the canister assembly (See REMOVAL ).
  NOTE: When replacing the canister, check the canister pump module interior and related pipes for water, fuel and other liquids. If liquids are present, check for disconnections and/or cracks in the following: 1) the pipe from the air inlet port to the canister pump module; 2) the canister filter; and 3) the fuel tank vent hose.
  
  Fig 24: Identifying Fuel Tank Hose, Air Inlet Port, Vent Hose And Inspection Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NEXT: Go to step 36
REPLACE PURGE VSV
1. Disconnect the connector and the hoses from the purge VSV.
2. Replace the purge VSV.
NEXT: Go to step 36

Fig 25: Identifying Purge VSV Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPAIR OR REPLACE HARNESS OR CONNECTOR
NEXT: Go to step 36
REPLACE PURGE LINE (INTAKE MANIFOLD - PURGE VSV)
NEXT: Go to step 36
INSPECT INTAKE MANIFOLD (EVAP PURGE PORT)
1. Check that the EVAP purge port of the intake manifold is not clogged. If necessary, replace the intake manifold.
NEXT: Go to step 36
REPLACE ECM
1. Replace the ECM (See REMOVAL ).
NEXT: Go to step 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.
NEXT: Go to step 36
PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
NOTE:
- The Evaporative System Check (Automatic Mode) consists of 5 steps performed automatically by the Techstream. It takes a maximum of approximately 18 minutes.
- Do not perform the Evaporative System Check when the fuel tank is more than 90% full because the cut-off valve may be closed. If the cut-off valve is closed, the fuel tank leak check is not possible.
- 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 Evaporative System Check, keep the temperature below 35°C (95°F).
1. Clear DTCs (See DTC CHECK / CLEAR ).
2. Enter the following menus using the Techstream: Powertrain / Engine / Utility / Evaporative System Check / Automatic Mode.
3. After the Evaporative System Check is completed, check for pending DTCs by entering the following menus: Powertrain / Engine / Trouble Codes / Pending.
  HINT:
  
  If no pending DTCs are found, the repair has been successfully completed.
NEXT: END