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July 1: So it begins. Don't worry, this is not in the correct legal jurisdiction!

Inspection Procedure

HINT:

Read freeze frame data. Freeze frame data records engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, 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.

  1. CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0441, P0442, P0446 AND/OR P0456) 

    Result 

    DTC OUTPUT RESULT TABLE

    Display (DTC Output) Proceed to
    Only P0441, P0442, P0446 and / or P0456 are output A
    P0451, P0452 and P453 are output B

    HINT:

    If any other DTCs besides P0441, P0442, P0446 and/or P0456 are output, perform the troubleshooting for those DTCs first (reference: P0451, P0452, P0453 are vapor pressure sensor malfunctions).

    B: Go to RELEVANT DTC CHART (See  DIAGNOSTIC TROUBLE CODE CHART  ) 

    A: Go to next step 

  2. CHECK CURRENT AND PENDING DTC 
    1. Check current DTCs. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBDII, DTC INFO and CURRENT DTCS.
    2. Check pending DTCs. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBDII, DTC INFO and PENDING DTCS.

    Result 

    CURRENT AND PENDING DTC - REFERENCE TABLE

    Current DTC Pending DTC Conclusion
    Set Set System has been malfunctioning. Problem can be specified.
    Set - System was malfunctioning in previous driving cycle. Problem may be specified.
    - Set System is malfunctioning. This is intermittent problem and caused by fuel tank cap loosing. Otherwise, this problem may be difficult to eliminate.

    HINT:

    The ECM stores the current DTC and illuminates the MIL when an emission-related component is malfunctioning in 2 consecutive driving cycles (2 trips). The MIL is turned OFF, if the component is functioning normally in 3 consecutive driving cycles. The ECM erases the current DTC, if the component is functioning normally in 40 consecutive driving cycles.

    The ECM stores the pending DTC when If the component is malfunctioning in present driving cycle (1 trip).

    The ECM erases the pending DTC, if the component is functioning normally in the next driving cycle.

    Go to next step 

  3. PREDICT POSSIBLE MALFUNCTION AREA 

    Predict possible malfunction area using the matrix below.

    EVAP DTC Matrix 

    EVAP DTC MATRIX - MALFUNCTION REFERENCE

    DTCs Malfunction Area P0441 P0442 P0446 P0451 P0452 P0453 P0455 P0456
    EVAP VSV stuck closed x   x       x  
    EVAP VSV stuck open x              
    EVAP small leak (0.04 inch)   x            
    CCV stuck closed     x          
    CCV stuck open x   x       x  
    FTP sensor malfunction       x        
    FTP sensor low output         x      
    FTP sensor high output           x    
    Gross leak x           x  
    EVAP small leak (0.02 inch)   x           x
    DTC AND SUSPECTED MALFUNCTION - REFERENCE TABLE

    DTCs Suspected Malfunction Area
    P0441 only EVAP VSV stuck open
    P0446 only CCV (vent valve) stuck open
    P0442 and/or P0456 Small leak

    Go to next step 

  4. PERFORM EVAP SYSTEM CHECK 
    NOTE: The EVAP system check can be used for confirmation after the EVAP system repair. Check DTCs after performing the EVAP system check. If no pending DTC is set, the EVAP system is functioning normally and the repair is completed.
    1. Select the "mmHg" unit. Select the hand-held tester menus: DIAGNOSIS, SETUP, UNIT CONVERSION and VAPOR PRESS.
    2. Allow the engine to idle.
    3. Perform the EVAP system check to find a malfunction area. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD II, SYSTEM CHECK and LEV II SYS CHECK.
    4. Read NOTICE and press ENTER.

    HINT:

    The EVAP system check is most accurate when the following conditions are being set:

    • Atmospheric pressure is 762 mmHg (sea level).
    • The engine coolant and intake air temperatures are 4 to 35° C (40 to 90° F).
    • The fuel tank level is 1/4 to 3/4.

    Diagram of LEVII EVAP System Check 

    Fig 1: Identifying Diagram Of LEVII EVAP System Check
    G04389345Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  5. EVAP SYSTEM CHECK STEP 1 (INITIALIZE SYSTEM) 
    Fig 2: Checking EVAP System - Step 1 (Initialize System)
    G04389346Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Wait for 30 seconds.

    Fig 3: Identifying LEVII System Check Screen
    G04389347Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Go to next step 

  6. EVAP SYSTEM CHECK STEP 2 (CHECK FOR CCV) 
    Fig 4: Checking EVAP System - Step 2 (For CCV)
    G04389348Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    1. Press RIGHT to go to step 2.
    2. Wait for 30 seconds and check VAPOR PRESS (EVAP pressure).
    Fig 5: Identifying LEVII System Check Screen
    G04389349Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    CHECKING EVAP PRESSURE - REFERENCE TABLE

    VAPOR PRESS Conclusion Proceed to
    Higher than 752 mmHg-a (-10 mmHg-g) Trouble area has not been found yet. OK
    Lower than 752 mmHg-a (-10 mmHg-g) Following problems are suspected:
    • Air inlet line restriction
    • Canister filter restriction
    • CCV (vent valve) stuck closed
    		 NG

    HINT:

    In this step, the intake manifold pressure (vacuum) is applied to the EVAP system. However, the fuel tank pressure does not drop due to the CCV (vent valve) open.

    NG: Go to step   11 

    OK: Go to next step 

  7. EVAP SYSTEM CHECK STEP 3 (INITIALIZE SYSTEM) 
    Fig 6: Checking EVAP System - Step 3 (Initialize System)
    G04389350Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    1. Press RIGHT to go to step 3.
    2. Wait for 30 seconds.
    Fig 7: Identifying LEVII System Check Screen
    G04389351Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Go to next step 

  8. EVAP SYSTEM CHECK STEP 4 (CHECK FOR EVAP VSV STUCK OPEN) 
    Fig 8: Checking EVAP System - Step 4 (EVAP VSV Stuck Open)
    G04389352Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    1. Press RIGHT to go to step 4.
    2. Wait for 15 seconds and check VAPOR PRESS (EVAP pressure).
    Fig 9: Identifying LEVII System Check Screen
    G04389353Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    CHECKING EVAP PRESSURE - REFERENCE TABLE

    VAPOR PRESS Conclusion Proceed to
    Higher than 758 mmHg-a (-4 mmHg-g) Trouble area has not been found yet. OK
    Lower than 758 mmHg-a (-4 mmHg-g) EVAP VSV stuck open NG

    NG: Go to step   14 

    OK: Go to next step 

  9. EVAP SYSTEM CHECK STEP 5 (APPLYING VACUUM) 
    Fig 10: Checking EVAP System - Step 5 (Applying Vacuum)
    G04389354Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    1. Press RIGHT to go to step 5.
    2. Wait for 30 seconds and check VAPOR PRESS (EVAP pressure).
    Fig 11: Identifying LEVII System Check Screen
    G04389355Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    CHECKING EVAP PRESSURE - REFERENCE TABLE

    VAPOR PRESS Conclusion Proceed to
    Lower than 748 mmHg-a (-14 mmHg-g) Trouble area has not been found yet. A
    756 to 768 mmHg-a (-6 to 6 mmHg-g) Following problems are suspected:
    • Fuel tank cap loosening
    • Gross leak
    • EVAP VSV stuck closed
    • CCV (vent valve) stuck open
    • Purge line blockage between fuel tank and canister
    		 B
    748 to 755 mmHg-a (-14 to -7 mmHg-g) Medium leak C
    NOTE:
    • If the pressure is lower than 740 mmHg-a (-22 mmHg-g), the hand-held tester closes the EVAP VSV.
      Fig 12: Identifying LEVII System Check Screen
      G04389356Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    • If the pressure is lower than 735 mmHg-a (-27 mmHg-g), the hand-held tester cancels the EVAP system check.
    Fig 13: Identifying LEVII System Check Screen - Error
    G04389357Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    B: Go to step 15 

    C: Go to step 18 

    A: Go to next step 

  10. EVAP SYSTEM CHECK STEP 6 (LEAK CHECK FOR EVAP SYSTEM) 
    Fig 14: Checking EVAP System - Step 6 (Leak Check For EVAP System)
    G04389358Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    1. Press RIGHT to go to step 6 when the VAPOR PRESS (EVAP pressure) is lower than 742 mmHg-a (-20 mmHg- g).
    2. Wait for 300 seconds and check VAPOR PRESS (EVAP pressure).
    Fig 15: Identifying LEVII System Check Screen
    G04389359Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    CHECKING EVAP PRESSURE - REFERENCE TABLE

    VAPOR PRESS Conclusion Proceed to
    Less than 758 mmHg-a (-4 mmHg-g) EVAP system is functioning normally. OK
    Higher than 758 mmHg-a (-4 mmHg-g) Leakage NG

    NG: Go to step   18 

    OK: Go to step   40 

  11. CHECK CCV 
    1. Turn the ignition switch to OFF
    2. Turn the ignition switch ON
    3. Switch the CCV (vent valve) using the hand-held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD II, ACTIVE TEST and CAN CTRL VSV.
    4. Touch the CCV and check the operation during switching the CCV.
    Fig 16: Checking CCV
    G04389360Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    CCV REFERENCE TABLE

    CCV (Vent Valve) Conclusion Proceed to
    CCV is operated CCV is functioning normally. OK
    CCV is not operated CCV is malfunctioning. NG

    NG: Go to step   25 

    OK: Go to next step 

  12. CHECK AIR INLET LINE RESTRICTION 
    1. Disconnect the air inlet line from the CCV.
    2. Remove and reinstall the fuel tank cap to release the fuel tank pressure.
    3. Allow the engine to idle.
      Fig 17: Checking Air Inlet Line Restriction
      G04389361Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    4. Perform step 2 of the EVAP system check.
    5. Wait for 30 seconds and check VAPOR PRESS (EVAP pressure).
      Fig 18: Identifying LEVII System Check Screen
      G04389362Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

      Result 

      CHECKING EVAP PRESSURE - REFERENCE TABLE

      VAPOR PRESS Conclusion Proceed to
      Higher than 752 mmHg-a (-10 mmHg-g) Blockage in canister filter A
      Lower than 752 mmHg-a (-10 mmHg-g) Blockage in CCV (vent valve) or canister B
    6. Reconnect the air inlet line to the CCV.

    B: Go to step 13 

    A: REPLACE CANISTER FILTER 

  13. CHECK CANISTER BLOCKAGE 
    1. Turn the ignition switch to OFF.
    2. Remove the CCV from the canister.
    3. Remove and reinstall the fuel tank cap to release the fuel tank pressure.
    4. Allow the engine to idle.
      Fig 19: Checking Canister Blockage
      G04389363Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    5. Perform step 2 of the EVAP system check.
    6. Wait for 30 seconds and check VAPOR PRESS (EVAP pressure).
    Fig 20: Identifying LEVII System Check Screen
    G04389364Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    CHECKING EVAP PRESSURE - REFERENCE TABLE

    VAPOR PRESS Conclusion Proceed to
    Higher than 752 mmHg-a (-10 mmHg-g) CCV (vent valve) stuck closed A
    Lower than 752 mmHg-a (-10 mmHg-g) Blockage in canister B

    B: CHECK AND REPLACE CHARCOAL CANISTER (See  CHARCOAL CANISTER ASSY (2AZ-FE) (FROM JULY, 2003)  ) 

    A: REPLACE CCV (VENT VALVE) 

  14. CHECK EVAP VSV (FOR EVAP VSV STUCK OPEN) 
    1. Turn the ignition switch to OFF.
    2. Disconnect the purge hose of the canister from the EVAP VSV.
    3. Disconnect the EVAP VSV connector.
    4. Allow the engine to idle.
    5. Touch the EVAP VSV port to check the vacuum.
    Fig 21: Checking EVAP VSV (For EVAP VSV Stuck Open)
    G04389365Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    EVAP VSV REFERENCE TABLE

    EVAP VSV Conclusion Proceed to
    Vacuum is applied. EVAP VSV is malfunctioning. A
    No vacuum is applied. Electrical circuit of EVAP VSV is malfunctioning. B

    B: Go to step   29 

    A: REPLACE EVAP VSV 

  15. CHECK FUEL TANK CAP 
    1. Remove the fuel tank cap and reinstall it until a few click sound is heard.
    2. Clear the DTCs.
    3. Check pending DTCs after the EVAP system check. If no pending DTC is set, the DTC (s) was set due to the fuel cap loosening.

    If necessary, replace the fuel cap.

    NG: Go to step 16 

    OK: REPAIR IS COMPLETE 

  16. CHECK EVAP VSV (FOR EVAP VSV STUCK CLOSED) 
    1. Disconnect the purge hose of the canister from the EVAP VSV.
    2. Allow the engine to idle.
    3. Switch the EVAP VSV using the hand-held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD II, ACTIVE TEST and EVAP VSV.
    4. Touch the EVAP VSV port to check the vacuum.

    HINT:

    The EVAP VSV can be tested with the EVAP Test Equipment (go to step  39).

    Fig 22: Checking EVAP VSV (For EVAP VSV Stuck Closed)
    G04389366Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    EVAP VSV - REFERENCE TABLE

    EVAP VSV Conclusion Proceed to
    Vacuum is applied when EVAP VSV is ON.
    No vacuum is applied when EVAP VSV is OFF.    		 EVAP VSV is functioning normally. OK
    No vacuum is applied when EVAP VSV is ON. Electrical circuit of EVAP VSV is malfunctioning. NG

    NG: Go to step   31 

    OK: Go to next step 

  17. CHECK CCV (FOR CCV STUCK OPEN) 
    1. Turn the ignition switch to OFF.
    2. Remove the CCV (vent valve) and plug the canister.
    3. Allow the engine to idle.
      Fig 23: Checking CCV (CCV Stuck Open)
      G04389367Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    4. Apply vacuum to the EVAP system with the EVAP system check. Perform step 5 "Applying Vacuum".
    5. Wait for 30 seconds and check the VAPOR PRESS (EVAP pressure).
    Fig 24: Identifying LEVII System Check Screen
    G04389368Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    CHECKING EVAP PRESSURE - REFERENCE TABLE

    VAPOR PRESS Conclusion Proceed to
    Lower than 747 mmHg-a (-15 mmHg-g) CCV (vent valve) stuck open A
    Higher than 747 mmHg-a (-15 mmHg-g) Blockage in canister
    Blockage in purge line (Fuel tank - Canister)
    Blockage in purge line (Fuel tank -EVAP VSV)    		 B

    B: Go to step   20 

    A: Go to step   24 

  18. CHECK FUEL TANK CAP 
    1. Remove the fuel tank cap and reinstall it until a few click sound is heard.
    2. Clear the DTCs.
    3. Check pending DTCs after the EVAP system check. If no pending DTC is set, the DTC (s) was set due to the fuel cap loosening.

      If necessary, replace the fuel cap.

    NG: Go to step 19 

    OK: REPAIR IS COMPLETE 

  19. CHECK FILLER NECK DAMAGE 
    1. Remove the fuel tank cap.
    2. Visually inspect the filler neck for damage.
    3. Reinstall the fuel tank cap.

    HINT:

    A leak point may be found with the EVAP Test Equipment (go to step  36).

    Fig 25: Identifying Fuel Tank Filler Neck
    G04389369Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    NG: REPLACE FUEL TANK INLET PIPE 

    OK: Go to next step 

  20. CHECK PURGE LINE (CANISTER - FUEL TANK) 
    1. Check that the pipes and hoses are connected correctly.
    2. Check that the pipes and hoses are not loose or disconnected.
    3. Check the pipes and hoses have no damage or blockage.
    Fig 26: Identifying Pipes And Hoses
    G04389370Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    NG: REPLACE PURGE HOSE 

    OK: Go to next step 

  21. CHECK PURGE LINE (CANISTER - EVAP VSV) 
    1. Check that the pipes and hoses are connected correctly.
    2. Check that the pipes and hoses are not loose or disconnected.
    3. Check the pipes and hoses have no damage or blockage.

    NG: REPLACE PURGE HOSE 

    OK: Go to next step 

  22. INSPECT CANISTER (See  EMISSION CONTROL SYSTEM (2AZ-FE) (FROM JULY, 2003)  ) 

    NG: REPLACE CANISTER 

    OK: Go to next step 

  23. INSPECT FUEL TANK 
    1. Check that the fuel tank has no damage.
    2. Check the fuel inlet pipe has no damage.
    3. Check leakage from the fuel pump unit.

    NG: REPAIR OR REPLACE DEFECTIVE OR DAMAGED PARTS 

    OK: Go to step   40 

  24. CHECK CCV 
    1. Stop the engine and turn the ignition switch ON.
    2. Switch the CCV (vent valve) using the hand-held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD II, ACTIVE TEST and CAN CTRL VSV.
    3. Touch the CCV and check the operation during switching the CCV.
    Fig 27: Checking CCV
    G04389371Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    CCV REFERENCE TABLE

    CCV (Vent Valve) Conclusion Proceed to
    CCV is operated Electrical circuit of CCV is functioning normally. A
    CCV is not operated Electrical circuit of CCV is malfunctioning. B

    B: Go to step   26 

    A: Go to next step 

  25. CHECK CCV 
    1. Turn the ignition switch OFF.
    2. Remove the CCV (vent valve).
    3. Connect the CCV connector,
    4. Turn the ignition switch ON.
    5. Switch the CCV using the hand-held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD II, ACTIVE TEST and CAN CTRL VSV.
    6. Apply air to the CCV port using an air gun and check the airflow.
    Fig 28: Checking CCV
    G04389372Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    CCV REFERENCE TABLE

    CCV (Vent Valve) Conclusion Proceed to
    Air flows when CCV is OFF (open).
    Air does not flows when CCV is ON (close).    		 CCV is functioning normally.
    Electrical circuit of CCV is malfunctioning.    		 A
    Air flows when CCV is ON (close).
    Air does not flows when CCV is OFF (open).    		 CCV is malfunctioning. B

    B: REPLACE CCV (See  VENTILATION VALVE SUB-ASSY (2AZ-FE) (FROM JULY, 2003)  ) 

    A: Go to next step 

  26. CHECK WIRE HARNESS AND CONNECTOR (CCV - POWER SOURCE) 
    1. Turn the ignition switch OFF.
    2. Disconnect the CCV connector.
    3. Turn the ignition switch ON.
    4. Measure the voltage between terminal 2 of the wire harness side connector and body ground.
    Fig 29: Measuring Voltage Between Wire Harness Side Connector Terminal 2 And Body Ground
    G04389373Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    CCV - POWER SOURCE - VOLTAGE TABLE

    Voltage Conclusion Proceed to
    Battery voltage Wire harness (CCV - Power source) is OK. OK
    0 to 3 V Wire harness (CCV - Power source) is short circuit. NG

    NG: REPAIR OR REPLACE WIRE HARNESS 

    OK: Go to next step 

  27. CHECK WIRE HARNESS AND CONNECTOR (CCV - ECM) 
    1. Switch the CCV using the hand-held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD II, ACTIVE TEST and CAN CTRL VSV.
    2. Measure the resistance between terminal 1 of the wire harness side connector and body ground.
    Fig 30: Measuring Resistance Between Wire Harness Side Connector Terminal 1 And Body Ground
    G04389374Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    CCV - ECM - RESISTANCE TABLE

    Resistance Conclusion Proceed to
    More than 10 kΩ when CCV is OFF.
    Less than 10 Ω when CCV is ON.    		 ECM and wire harness (CCV - ECM) are OK.
    CCV is malfunctioning.    		 OK
    No change Either of wire harness (CCV - ECM) or ECM is malfunctioning. NG

    NG: Go to step 28 

    OK: REPLACE CCV 

  28. CHECK WIRE HARNESS AND CONNECTOR (CCV - ECM) 
    1. Check the wire harness between the ECM and CCV.
    1. Disconnect the E8 ECM connector.
    2. Disconnect the V15 VSV connector for CCV.
    3. Measure the resistance between the wire harness side connectors.

    Standard: 

    CCV - ECM - RESISTANCE TABLE

    Tester Connection Specified Condition
    E8-27 (CCV) - V15-1 Below 1 Ω
    V15-1 - Body ground 10 kΩ or higher
    Fig 31: Disconnecting E6 ECM Connector
    G04389375Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    NG: REPAIR OR REPLACE HARNESS AND CONNECTOR 

    OK: CHECK AND REPLACE ECM 

  29. CHECK EVAP VSV 
    1. Turn the ignition switch ON.
    2. Switch the EVAP VSV using the hand-held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD II, ACTIVE TEST and EVAP VSV (Alone).
    3. Listen to click sounds to check the EVAP VSV operation.
    Fig 32: Checking EVAP VSV Operation
    G04389376Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    EVAP VSV - REFERENCE TABLE

    EVAP VSV Conclusion Proceed to
    Operated Electrical circuit of EVAP VSV is functioning normally. OK
    Not operated Electrical circuit of EVAP VSV is malfunctioning. NG

    NG: Go to step   32 

    OK: Go to next step 

  30. CHECK EVAP VSV 
    1. Disconnect the purge hose of the canister from the EVAP VSV.
    2. Start the engine.
    3. Switch the EVAP VSV using the hand-held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD II, ACTIVE TEST and EVAP VSV.
    4. Touch the EVAP VSV port to check the vacuum.

    HINT:

    The EVAP VSV can be tested with the EVAP Test Equipment (go to step  39).

    Fig 33: Checking EVAP VSV
    G04389377Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    EVAP VSV - REFERENCE TABLE

    EVAP VSV Conclusion Proceed to
    Vacuum is applied when EVAP VSV is ON.
    No vacuum is applied when EVAP VSV is OFF.    		 EVAP VSV is functioning normally. OK
    No vacuum is applied when EVAP VSV is ON. Electrical circuit of EVAP VSV is malfunctioning. NG

    NG: Go to step 32 

    OK: Go to next step 

  31. CHECK PURGE LINE (EVAP VSV - THROTTLE BODY) 
    1. Check that the vacuum hoses are connected correctly.
    2. Check that the vacuum hoses are not loose or disconnected.
    3. Check the vacuum hoses and tubes for cracks, holes, damage, or blockage.
    Fig 34: Checking Purge Line
    G04389378Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    NG: REPLACE PURGE HOSE 

    OK: REPLACE EVAP VSV 

  32. INSPECT EVAP VSV 
    1. Turn the ignition switch OFF.
    2. Disconnect the EVAP VSV connector.
    3. Measure the resistance of the EVAP VSV.
      4. Fig 35: Measuring Resistance Of EVAP VSV
      G04389379Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Standard 

    EVAP VSV - RESISTANCE TABLE

    Tester Connection Specified Condition
    Between terminals 26 to 30 Ω at 20°C (68°F)
    Each terminal - Body ground 10 kΩ or more

    NG: REPLACE EVAP VSV 

    OK: Go to next step 

  33. INSPECT EVAP VSV 
    1. Remove the EVAP VSV.
    2. Apply air to the EVAP VSV using an air gun, check the airflow.
      Fig 36: Inspecting EVAP VSV Airflow
      G04389380Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    3. Apply battery positive voltage across the terminals.
    4. Apply air to the EVAP VSV using an air gun, check the airflow.
      Fig 37: Applying Battery Positive Voltage Across Terminals And Checking Airflow
      G04389381Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    EVAP VSV - REFERENCE TABLE

    EVAP VSV Conclusion Proceed to
    Air does not flow when EVAP VSV is OFF.
    Air flows when EVAP VSV is ON.    		 EVAP VSV is functioning normally. OK
    Air flows when EVAP VSV is OFF.
    Air does not flow when EVAP VSV is ON.    		 EVAP VSV is malfunctioning. NG

    NG: REPLACE EVAP VSV 

    OK: Go to next step 

  34. CHECK WIRE HARNESS AND CONNECTOR (EVAP VSV - POWER SOURCE) 
    1. Turn the ignition switch ON.
    2. Measure the voltage between the terminal 1 of the wire harness side and body ground.
    Fig 38: Identifying EVAP VSV Connector Terminals
    G04389382Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Result 

    EVAP VSV - POWER SOURCE - VOLTAGE TABLE

    Voltage Conclusion Proceed to
    Battery voltage Wire harness (EVAP VSV - Power source) is OK. OK
    0 to 3 V Wire harness (EVAP VSV - Power source) is short circuit. NG

    NG: REPAIR OR REPLACE HARNESS AND CONNECTOR 

    OK: Go to next step 

  35. CHECK WIRE HARNESS AND CONNECTOR (EVAP VSV - ECM) 
    1. Disconnect the ECM connector.
    2. Measure the voltage of ECM connector and body ground.
      3. Fig 39: Disconnecting ECM Connector
      G04389383Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Standard: 

    EVAP VSV - ECM - VOLTAGE TABLE

    Tester Connection Specified condition
    E8-34 (PRG) - Body ground 9 to 14 V

    NG: REPAIR OR REPLACE HARNESS AND CONNECTOR 

    OK: CHECK AND REPLACE ECM 

  36. CHECK FUEL TANK CAP 
    1. Connect the fuel tank cap to the gas cap adaptor.
    2. Connect the pressure hose from the pump to the gas cap adaptor.
    3. Plug the gas cap adaptor port.
    4. Turn the pump ON and pressurize the gas cap adaptor by 24 - 28 mmHg. If the pressure does not reach to 24 mmHg within 45 seconds, stop the pump. The fuel tank cap is malfunctioning.
    5. Turn the pump OFF and seal the pressure line to maintain the pressure.
    6. Measure the pressure change for 2 minutes. If the pressure drops to lower than 15 mmHg, the fuel tank cap is malfunctioning.

      Standard: The fuel tank cap keeps the pressure that is 15 mmHg or higher. 

    NG: REPLACE FUEL TANK CAP 

    OK: Go to next step 

  37. CHECK LEAK 
    NOTE: DO NOT apply the EVAP system to the pressure that is higher than 35 mmHg. The EVAP system will be damaged.
    1. Connect the pressure line from the pump to the EVAP service port.
    2. Turn the ignition switch ON but the engine is not running.
    3. Turn the CCV (vent valve) is ON (close) using the hand-held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD II, ACTIVE TEST and CAN CTRL VSV.
    4. Turn the pump ON and pressurize the EVAP system by 24 - 28 mmHg.
    5. Turn the pump OFF and seal the pressure line to maintain the pressure. If the pressure does not reach to 24 mmHg within 45 seconds, stop the pump. A leakage is in the EVAP system. If the system has a small leak, a whistling sound may be heard.
    6. Measure the pressure change for 2 minutes. If the pressure drops to lower than 15 mmHg, a leakage is in the EVAP system.

      Standard: The EVAP system keeps the pressure that is 15 mmHg or higher. 

    NG: Go to step 38 

    OK: NO LEAKAGE IN EVAP SYSTEM 

  38. LOCK FOR LEAK POINT 
    1. Apply the soapy water on suspected components.
    2. Turn the CCV (vent valve) is ON (close) using the hand- held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD II, ACTIVE TEST and CAN CTRL VSV.
    3. Turn the pump ON and pressurize the EVAP system by 24 - 28 mmHg.
    4. Turn the pump OFF and seal the pressure line to maintain the pressure. If the pressure does not reach to 24 mmHg within 45 seconds, stop the pump.
    5. Check bubbles to find the leak points:
      • EVAP service port
      • Canister
      • Hose connections/Lines
      • Fuel cap
      • Fuel filler neck
      • Purge line
      • EVAP VSV
      • CCV (vent valve)
      • Fuel pump sending unit
    6. Repair or replace the leak component.
    7. Perform the EVAP system check to confirm no leak.
    Fig 40: Identifying Leakage Points
    G04389384Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Go to step   4 

  39. CHECK EVAP VSV 
    1. Connect the vacuum gauge to the EVAP service port.
      1. Start the engine.
      2. Switch the EVAP VSV using the hand-held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD II, ACTIVE TEST and EVAP VSV.
      3. Check the vacuum when switching the EVAP VSV. If the vacuum gauge indicates negative value when the EVAP VSV is ON, the EVAP VSV is functioning normally.
        Fig 41: Connecting Vacuum Gauge To EVAP Service Port
        G04389385Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

        OK: The vacuum gauge indicates negative value when the EVAP VSV is ON. 

    NG: Go to step   31 

    OK: Go to step   17 

  40. CHECK MONITOR STATUS AND DTC 
    1. Clear DTCs.
    2. Perform a drive pattern test (see READINESS MONITOR DRIVE PATTERN ).
    3. Check that the monitor result is PASS.
    4. Confirm no pending DTC.

      REPAIR IS COMPLETE 

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