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Home >> Toyota >> 2005 >> MR2 C65M >> Repair and Diagnosis >> Engine Performance >> System >> Engine - Diagnostics >> DTC P0441, P0446: Evaporative Emission Control System Incorrect Purge Flow/Vent Control Circuit >> Inspection Procedure

Inspection Procedure

HINT:

Hand-held tester: 

  1. Check that fuel tank cap meets OEM specifications. 
    • NG: Replace with a cap that meets OEM specifications. 
    • OK: Go to next step. 
  2. Check that fuel tank cap is correctly installed. 
    • NG: Correctly install fuel tank cap. 
    • OK: Go to next step. 
  3. Check fuel tank cap (See  INSPECTION  ). 
    • NG: Replace fuel tank cap. 
    • OK: Go to next step. 
  4. Check filler neck for damage. 

    PREPARATION: 

    Remove the fuel tank cap.

    CHECK: 

    Visually inspect the filler neck for damage.

    • NG: Replace filler pipe. 
    • OK: Go to next step. 
  5. Check purge flow. 

    PREPARATION: 

    1. Connect the hand-held tester to the DLC3.
    2. Perform the ACTIVE TEST by selecting the following menus: ENHANCED OBD II / ACTIVE TEST.
    3. Disconnect the vacuum hose for the EVAP VSV from the charcoal canister.
    4. Start the engine.
    5. In the ACTIVE TEST menu, select: EVAP VSV (ALON) / ALL. Operate the EVAP VSV (press the right or left buttons).

    CHECK: 

    When the EVAP VSV is operated by the hand-held tester, check whether the disconnected hose applies suction to your finger.

    OK: 

    VSV is ON: 

    Disconnected hose applies suction to your finger. 

    VSV is OFF: 

    Disconnected hose applies no suction to your finger. 

    Fig 1: Checking Purge Flow
    G02652941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • OK: Go to step   9 . 
    • NG: Go to next step. 
  6. Check vacuum hose between intake manifold and EVAP VSV, and EVAP VSV and charcoal canister. 

    CHECK: 

    1. Check that the vacuum hose is connected correctly.
    2. Check the vacuum hose for looseness and disconnection.
    3. Check the vacuum hose for cracks, holes, damage and blockage.
    • NG: Repair or replace vacuum hoses. 
    • OK: Go to next step. 
  7. Check operation of EVAP VSV (See  INSPECTION  ). 
    • NG: Replace EVAP VSV. 
    • OK: Go to next step. 
  8. Check for open and short in harness and connectors between EFI MAIN relay (Marking: EFI) and EVAP VSV, and EVAP VSV and ECM (See  HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE  ). 
  9. Check CCV. 

    PREPARATION: 

    1. Disconnect the vacuum hose for the CCV from the charcoal canister.
    2. Turn the ignition switch to ON and turn the hand-held tester main switch ON.
    3. Perform the ACTIVE TEST by selecting the following menus: ENHANCED OBD II / ACTIVE TEST.
    4. In the ACTIVE TEST menu, select: CAN CTRL VSV / ALL. Operate the CAN CTRL VSV (press the right or left buttons).

    CHECK: 

    Check the CCV operation when it is operated by the hand-held tester.

    OK: 

    CCV is ON: 

    Air does not flow from port E to port F. 

    CCV is OFF: 

    Air from port E flows out through port F. 

    Fig 2: Checking CCV
    G02652942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • OK: Go to step   13 . 
    • NG: Go to next step. 
  10. Check vacuum hose between CCV and charcoal canister. 

    CHECK: 

    1. Check that the vacuum hose is connected correctly.
    2. Check the vacuum hose for looseness and disconnection.
    3. Check the vacuum hose for cracks, holes damage and blockage.
    • NG: Repair or replace vacuum hoses. 
    • OK: Go to next step. 
  11. Check operation of CCV (See  INSPECTION  ). 
    • NG: Replace CCV. 
    • OK: Go to next step. 
  12. Check for open and short in harness and connectors between EFI MAIN relay (Marking: EFI) and CCV, and CCV and ECM (See  HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE  ). 
  13. Check pressure switching VSV. 

    PREPARATION: 

    1. Turn the ignition switch to ON and turn the hand-held tester main switch ON.
    2. Perform the ACTIVE TEST by selecting the following menus: ENHANCED OBD II / ACTIVE TEST.
    3. In the ACTIVE TEST menu, select: TANK PRESSURE SWITCHING VSV / ALL. Operate the TANK PRESSURE SWITCHING VSV (press the right or left buttons).

    CHECK: 

    Check the VSV operation when it is operated by the hand-held tester.

    OK: 

    VSV is ON: 

    Air from port E flows out through port F. 

    VSV is OFF: 

    Air does not flow from port E to port F. 

    Fig 3: Checking VSV
    G02652943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • OK: Go to step   16 . 
    • NG: Go to next step. 
  14. Check operation of pressure switching VSV (See  INSPECTION  ). 
    • NG: Replace pressure switching VSV. 
    • OK: Go to next step. 
  15. Check for open and short in harness and connectors between EFI MAIN relay (Marking: EFI), pressure switching VSV and ECM (See  HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE  ). 
  16. Check whether hose close to fuel tank has been modified, and check whether there are signs of any damage near fuel tank. 

    CHECK: 

    Check for cracks, deformation and loose connection of the following parts:

    • Fuel tank
    • Fuel tank filler pipe
    • Hoses and tubes around fuel tank
    Fig 4: Checking Whether Hose Close To Fuel Tank Is Modified And Damage Near Fuel Tank
    G02652944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • NG: Repair or replace evaporative emission leak part. 
    • OK: Go to next step. 
  17. Check vacuum hoses between vapor pressure sensor and fuel tank, charcoal canister and pressure switching VSV. 

    CHECK: 

    1. Check that the vacuum hose is connected correctly.
    2. Check the vacuum hose for looseness and disconnection.
    3. Check the vacuum hose for cracks, holes and damage.
    • NG: Repair or replace vacuum hose. 
    • OK: Go to next step. 
  18. Check hose and tube between fuel tank and charcoal canister. 

    CHECK: 

    1. Check for proper connection of the fuel tank and fuel EVAP pipe (See PARTS LAYOUT AND SCHEMATIC DRAWING ), fuel EVAP pipe and fuel tube under the floor, fuel tube under the floor and charcoal canister.
    2. Check the hose and tube for cracks, holes and damage.
    • NG: Repair or replace hose and tube. 
    • OK: Go to next step. 
  19. Check voltage between terminals VC and E2 of ECM connector. 

    CHECK: 

    1. Turn the ignition switch to ON.

    CHECK: 

    Measure the voltage between terminals VC and E2 of the ECM connector.

    OK: Voltage: 4.5 to 5.5 V 

    Fig 5: Checking Voltage Between Terminals VC And E2
    G02652945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. Check voltage between terminals PTNK and E2 of ECM connectors. 

    PREPARATION: 

    1. Turn the ignition switch to ON.

    CHECK: 

    Measure the voltage between terminals PTNK and E2 of the ECM connectors after confirming conditions (1) and (2).

    1. Disconnect the vacuum hose from the vapor pressure sensor.
    2. Using the MITYVAC (hand-held Vacuum Pump), apply a vacuum of 4.0 kPa (30 mmHg, 1.18 in.Hg) to the vapor pressure sensor.
    NOTE: Vacuum applied to vapor pressure sensor must be less than 66.7 kPa (500 mmHg, 19.7 in.Hg).

    OK: 

    Condition (1) Voltage: 2.9 to 3.7 V 

    Condition (2) Voltage: 0.5 V or less 

    Fig 6: Checking Voltage Between Terminals PTNK And E2
    G02652946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • OK: Go to step 22. 
    • NG: Go to next step. 
  21. Check for open and short in harness and connectors between vapor pressure sensor and ECM (See  HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE  ). 
  22. Check fuel tank inlet valve. 
    • NG: Replace fuel tank inlet valve. 
    • OK: Go to next step. 
  23. Check fuel tank. 
    • NG: Replace fuel tank. 
    • OK: Go to next step. 
  24. Check charcoal canister for cracks, holes and damage. 

OBD II scan tool (excluding the hand-held tester): 

  1. Check that fuel tank cap meets OEM specifications. 
    • NG: Replace with a cap that meets OEM specifications. 
    • OK: Go to next step. 
  2. Check that fuel tank cap is correctly installed. 
    • NG: Correctly install fuel tank cap. 
    • OK: Go to next step. 
  3. Check fuel tank cap (See  INSPECTION  ). 
    • NG: Replace fuel tank cap. 
    • OK: Go to next step. 
  4. Check filler neck for damage. 

    PREPARATION: 

    Remove the fuel tank cap.

    CHECK: 

    Visually inspect the filler neck for damage.

    • NG: Replace filler pipe. 
    • OK: Go to next step. 
  5. Check whether hose close to fuel tank has been modified, and check whether there are signs of any damage near fuel tank or charcoal canister. 

    CHECK: 

    Check for cracks, deformation and loose connection of the following parts:

    • Fuel tank
    • Charcoal canister
    • Fuel tank filler pipe
    • Hoses and tubes around fuel tank and charcoal canister
    Fig 7: Checking For Damage Near Fuel Tank Or Charcoal Canister
    G02652947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • NG: Repair or replace evaporative emission leakage point. 
    • OK: Go to next step. 
  6. Check vacuum hoses between vapor pressure sensor and fuel tank, charcoal canister and pressure switching VSV, and charcoal canister. 

    CHECK: 

    1. Check that the vacuum hose is connected correctly.
    2. Check the vacuum hose for looseness and disconnection.
    3. Check the vacuum hose for cracks, hole and damage.
    • NG: Repair or connect VSV or sensor connector. 
    • OK: Go to next step. 
  7. Check hose and tube between fuel tank and charcoal canister. 

    CHECK: 

    1. Check for proper connection of the fuel tank and fuel EVAP pipe (See PARTS LAYOUT AND SCHEMATIC DRAWING ), fuel EVAP pipe and fuel tube under the floor, fuel tube under the floor and charcoal canister.
    2. Check the hose and tube for cracks, hole and damage.
    • NG: Repair or replace hose and tube. 
    • OK: Go to next step. 
  8. Check vacuum hoses ((8), (9), (10) and (11) in  Figure  in circuit description). 

    CHECK: 

    1. Check that the vacuum hose is connected correctly.
    2. Check the vacuum hose for looseness and disconnection.
    3. Check the vacuum hose for cracks, hole damage and blockage.
    • NG: Repair or replace vacuum hose. 
    • OK: Go to next step. 
  9. Check connector for EVAP VSV, connector for CCV, connector for pressure switching VSV and vapor pressure sensor connector for looseness and disconnection. 
    • NG: Repair or connect sensor connector. 
    • OK: Go to next step. 
  10. Check charcoal canister for cracks, holes and damage. 
    • NG: Check and replace charcoal canister. 
    • OK: Go to next step. 
  11. Check voltage between terminals VC and E2 of ECM connector. 

    CHECK: 

    1. Turn the ignition switch to ON.

    CHECK: 

    Measure the voltage between terminals VC and E2 of the ECM connector.

    OK: Voltage: 4.5 to 5.5 V 

    Fig 8: Checking Voltage Between Terminals VC And E2
    G02652948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. Check voltage between terminals PTNK and E2 of ECM connectors. 

    PREPARATION: 

    1. Turn the ignition switch to ON.

    CHECK: 

    Measure the voltage between terminals PTNK and E2 of the ECM connectors after confirming conditions (1) and (2).

    1. Disconnect the vacuum hose from the vapor pressure sensor.
    2. Using the MITYVAC (Hand-held Vacuum Pump), apply a vacuum of 4.0 kPa (30 mmHg, 1.18 in.Hg) to the vapor pressure sensor.
    NOTE: Vacuum applied to vapor pressure sensor must be less than 66.7 kPa (500 mmHg, 19.7 in.Hg).

    OK: 

    Condition (1) Voltage: 2.9 to 3.7 V 

    Condition (2) Voltage: 0.5 V or less 

    Fig 9: Checking Voltage Between Terminals PTNK And E2
    G02652949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • OK: Go to step 14. 
    • NG: Go to next step. 
  13. Check for open and short in harness and connectors between vapor pressure sensor and ECM (See  HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE  ). 
  14. Check EVAP VSV. 

    PREPARATION: 

    1. Turn the ignition switch to ON.

    CHECK: 

    Check VSV function.

    1. Connect between terminal EVP1 of the ECM connector and body ground (VSV ON).
    2. Disconnect between terminal EVP1 of the ECM connector and body ground (VSV OFF).

    OK: 

    1. VSV is ON: 

      Air from port E flows out through port F. 

    2. VSV is OFF: 

      Air does not flow from port E to port F. 

    Fig 10: Checking EVAP VSV
    G02652950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • OK: Go to step 17. 
    • NG: Go to next step. 
  15. Check operation of EVAP VSV (See  INSPECTION  ). 
    • NG: Replace EVAP VSV. 
    • OK: Go to next step. 
  16. Check for open and short in harness and connectors between EFI MAIN relay (Marking: EFI) and EVAP VSV, and EVAP VSV and ECM (See  HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE  ) 
  17. Check CCV. 

    PREPARATION: 

    1. Turn the ignition switch to ON.

    CHECK: 

    Check the CCV function.

    1. Connect between terminal CCV of the ECM connector and body ground (CCV ON).
    2. Disconnect between terminal CCV of the ECM connector and body ground (CCV OFF).

    OK: 

    1. CCV is ON: 

      Air does not flow from port E to port F. 

    2. CCV is OFF: 

      Air from port E flows out through port F. 

    Fig 11: Checking CCV
    G02652951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • OK: Go to step 20. 
    • NG: Go to next step. 
  18. Check operation of CCV (See  INSPECTION  ). 
    • NG: Replace CCV. 
    • OK: Go to next step. 
  19. Check for open and short in harness and connectors between EFI MAIN relay (Marking: EFI) and CCV, and CCV and ECM (See  HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE  ). 
  20. Check pressure switching VSV. 

    PREPARATION: 

    1. Turn the ignition switch to ON.

    CHECK: 

    Check the VSV function.

    1. Connect between terminal TBP of the ECM connector and body ground (VSV ON).
    2. Disconnect between terminal TBP of the ECM connector and body ground (VSV OFF).

    OK: 

    1. VSV is ON: 

      Air from port E flows out through port F. 

    2. VSV is OFF: 

      Air does not flow from port E to port F. 

    Fig 12: Checking VSV
    G02652952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • OK: Go to step 23. 
    • NG: Go to next step. 
  21. Check operation of pressure switching VSV (See  INSPECTION  ). 
    • NG: Replace pressure switching VSV. 
    • OK: Go to next step. 
  22. Check for open and short in harness and connectors between EFI MAIN relay (Marking: EFI), pressure switching VSV and ECM (See  HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE  ). 
  23. Check fuel tank inlet valve. 
    • NG: Replace fuel tank inlet valve. 
    • OK: Go to next step. 
  24. Check fuel tank. 
    • NG: Replace fuel tank. 
    • OK: It is likely that vehicle user did not properly close fuel tank cap. 
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