Inspection Procedure

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

HINT:

Using the Techstream monitor results enables the EVAP system to be confirmed.
Read freeze frame data using the Techstream. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction.

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 Techstream to the DLC3.
5. Turn the ignition switch ON.
6. Enter the following menus: Powertrain / Engine and ECT / Trouble 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.
  
  NOTE: If the 0.02 inch leak criterion difference between the first and second checks is greater than the specification, the DTCs corresponding to the 0.02 inch leak criterion (P043E, P043F, P0441, P0455, P0456, P2401 and P2420) will all be stored.
  
  Fig 1: Identifying Malfunctioning Area Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
NOTE:
- The Evaporative System Check (Automatic Mode) consists of five 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, making the leak check of the fuel tank 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 the Evaporative System Check, keep the temperature below 35°C (95°F).
1. Clear the DTCs (See DTC CHECK/CLEAR ).
2. Enter the following menus: Powertrain / Engine and ECT / 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 and ECT / Trouble Codes / Pending.
  HINT:
  
  If no pending DTC is displayed, perform the CONFIRMATION DRIVING PATTERN. After this confirmation, check for pending DTCs. If no DTC is displayed, the EVAP system is normal.
PERFORM EVAP SYSTEM CHECK (MANUAL OPERATION)
NOTE:
- In the Evaporative System Check (Manual Mode), the series of 5 Evaporative System Check steps are performed manually by 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, making the leak check of the fuel tank 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 the Evaporative System Check, keep the temperature below 35°C (95°F).
1. Clear the DTCs (See DTC CHECK/CLEAR ).
2. Enter the following menus: Powertrain / Engine and ECT / Utility / Evaporative System Check / Manual Mode.

PERFORM EVAP SYSTEM CHECK (STEP 1/5)

Check the EVAP pressure in step 1/5.

Result

RESULT TABLE

DTC No. ⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

Virtually no variation in EVAP pressure

Not yet determined

P0451

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

Canister pressure sensor noise

⁽¹⁾	These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1.

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

B: Go to step 30

A: Go To Next Step

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

Fig 4: Identifying EVAP 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 TABLE

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 criterion

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 step 1.

HINT:

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

B: Go to step 23

A: Go To Next Step

PERFORM EVAP SYSTEM CHECK (STEP 2/5)

HINT:

Make a note of the pressures checked in the steps below.

Check the EVAP pressure 4 seconds after the leak detection pump is activated* [A}.

Check the EVAP pressure again when it has stabilized. This pressure is the 0.02 inch leak criterion [B}.

*: The leak detection pump begins to operate as step 1/5 proceeds to step 2/5.

Result

RESULT TABLE

DTC No. ⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

EVAP pressure in step [B] between -4.85 kPa and -1.06 kPa (-36.38 mmHg and -7.95 mmHg)

Not yet determined

P043F and P2401

EVAP pressure in step [B] -1.06 kPa (-7.95 mmHg) or more

Reference orifice high-How
Leak detection pump stuck OFF

P043E

EVAP pressure in step [B] below -4.85 kPa (-36.38 mmHg)

Reference orifice clogged

P2419

EVAP pressure in step [A] more than -1.06 kPa (-7.95 mmHg)

Vent valve stuck closed

⁽¹⁾	These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1.

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

B: Go to step 11

C: Go to step 30

D: Go to step 19

A: Go To Next Step

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

Check the EVAP pressure in step 3/5.

Result

RESULT TABLE

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

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 malfunction (stuck)

⁽¹⁾	These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1.

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

B: Go to step 20

C: Go to step 30

A: Go To Next Step

PERFORM EVAP SYSTEM CHECK (STEP 3/5)

Fig 7: Identifying EVAP Pressure Graph (Step 3/5)
Courtesy 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 (900 seconds).

PERFORM EVAP SYSTEM CHECK (STEP 4/5)

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 4/5.

Result

RESULT TABLE

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

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 intake manifold

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

⁽¹⁾	These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1.

B: Go to step 15

C: Go to step 12

A: Go To Next Step

PERFORM EVAP SYSTEM CHECK (STEP 5/5)

Fig 9: Identifying EVAP 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 0.02 inch leak criterion (step 5/5).

Result

RESULT TABLE

DTC No. ⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

EVAP pressure (step 3/5) lower than second 0.02 inch leak criterion (step 5/5)

Not yet determined

P0441 and P0455

EVAP pressure (step 3/5) higher than [second 0.02 inch leak criterion (step 5/5) x 0.2]

Purge VSV stuck open
EVAP gross leak

P0456

EVAP pressure (step 3/5) higher than second 0.02 inch leak criterion (step 5/5)

EVAP small leak

⁽¹⁾	These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1.

A: Go to step 36

B: Go to step 12

PERFORM EVAP SYSTEM CHECK (STEP 3/5)

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 3/5.

Result

RESULT TABLE

DTC No. ⁽¹⁾

Test Results

Suspected Trouble Areas

Proceed to

P043F

EVAP pressure less than [0.02 inch leak criterion] measured at 2/5

Reference orifice high-flow

P2401

EVAP pressure almost same as [0.02 inch leak criterion] 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 step 1.

HINT:

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

A: Go to step 30

B: Go to step 23

PERFORM ACTIVE TEST USING TECHSTREAM (PURGE VSV)

Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VSV for EVAP Control.
Disconnect the hose (connected to the canister) from the purge VSV.
Turn the ignition switch ON.
Using the tester, turn the purge VSV OFF.
Use your finger to confirm that the purge VSV has no suction.
Using the tester, turn the purge VSV ON.

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

Fig 11: Identifying Purge VSV & EVAP Hose

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT TABLE

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 intake manifold	C

B: Go to step 14

C: Go to step 15

A: Go To Next Step

CHECK FUEL CAP

Check that the fuel cap is correctly installed.
1. Tighten the fuel cap until a few click sounds are heard.
  HINT:
  
  If an EVAP tester is available, use the tester to check the fuel cap.
Remove the fuel cap and install it onto the fuel cap adaptor.
Connect an EVAP tester hose to the adaptor, and pressurize the cap to 3.2 to 3.7 kPa (24 to 28 mmHg) using an EVAP tester.
Seal the adaptor and wait for 2 minutes.
Check the pressure. If the pressure is 2 kPa (15 mmHg) or more, the fuel cap is normal.

Reinstall the fuel cap.

Result

RESULT TABLE

Test Results	Suspected Trouble Areas	Proceed to
Fuel cap correctly installed	-	A
Fuel cap loose	Fuel cap improperly installed Defective fuel cap Fuel cap does not meet OEM specifications	B
No fuel cap	-	C

A: Go to step 29

B: Go to step 27

C: Go to step 28

INSPECT PURGE VSV

Turn the ignition switch OFF.
Disconnect the V2 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: Identifying Purge VSV & Hose (1 Of 2)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Result

RESULT TABLE

Test Results	Suspected Trouble Areas	Proceed to
No suction	ECM	A
Suction applied	Purge VSV	B

Reconnect the purge VSV connector.

A: Go to step 35

B: Go to step 31

CHECK EVAP HOSE (PURGE VSV - INTAKE MANIFOLD)

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

Fig 13: Identifying Purge VSV & Hose (2 Of 2)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Start the engine.

Use your finger to confirm that the hose has suction.

Result

RESULT TABLE

Test Results	Suspected Trouble Areas	Proceed to
Suction applied	EVAP hose between purge VSV and intake manifold normal	A
No suction	Intake manifold port EVAP hose between purge VSV and intake manifold	B

B: Go to step 26

A: Go To Next Step

INSPECT PURGE VSV

Remove the purge VSV connector.

Fig 14: Identifying Duty Purge VSV
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply battery voltage to the terminals of the purge VSV.

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

Result

RESULT TABLE

Test Results	Suspected Trouble Areas	Proceed to
Air flows	Purge VSV normal	A
No air flows	Purge VSV	B

B: Go to step 31

A: Go To Next Step

CHECK HARNESS AND CONNECTOR (POWER SOURCE OF PURGE VSV)

Disconnect the V2 purge VSV connector.

Fig 15: Identifying V2 Purge VSV Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Turn the ignition switch ON.

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

Result

RESULT TABLE

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

Reconnect the purge VSV connector.

B: Go to step 32

A: Go To Next Step

CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM)

Disconnect the V2 purge VSV connector.
Disconnect the E4 ECM connector.

Measure the resistance of the wire harness side connectors.

Standard resistance

TESTER CONNECTION SPECIFIED CONDITION TABLE

Tester Connection	Specified Condition
V2-1 - PRG (E4-34)	Below 1 Ω
PRG (E4-34) - Body ground	10 kΩ or higher
V2-1 - Body ground	10 kΩ or higher

Reconnect the ECM connector.
Reconnect the purge VSV connector.

Fig 16: Identifying E4 ECM Connector

OK: Go to step 35

NG: Go to step 32

PERFORM ACTIVE TEST USING TECHSTREAM (FOR VENT VALVE)

Turn the ignition switch ON.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VSV for Vent Valve.

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.

Fig 17: Identifying ECM Connector

Result

RESULT TABLE

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

PERFORM ACTIVE TEST USING TECHSTREAM (FOR VENT VALVE)

Turn the ignition switch ON.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VSV for Vent Valve.

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.

Fig 18: Identifying ECM Connector

Result

RESULT TABLE

Test Results	Suspected Trouble Areas	Proceed to
Below 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

A: Go To Next Step

INSPECT CANISTER PUMP MODULE (POWER SOURCE FOR VENT VALVE)

Turn the ignition switch OFF.
Disconnect the L4 canister connector.

Fig 19: Identifying L4 Canister Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Turn the ignition switch ON.

Measure the voltage between terminal 9 of the canister connector and the body ground.

Result

RESULT TABLE

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

B: Go to step 32

A: Go To Next Step

INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION)

Turn the ignition switch OFF.
Disconnect the L4 canister connector.
Apply the battery voltage to terminals 9 and 8 of the canister pump module.

Fig 20: Applying Battery Voltage To Terminals 9 & 8 Of Canister Pump Module
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Result

RESULT TABLE

Test Results	Suspected Trouble Areas	Proceed to
Operating	Wire harness between vent valve and ECM	A
Not operating	Vent valve	B

Reconnect the canister connector.

A: Go to step 32

B: Go to step 30

PERFORM ACTIVE TEST USING TECHSTREAM (FOR LEAK DETECTION PUMP)

Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the Vacuum Pump.

Measure the voltage between MPMP terminal of the ECM connector and the body ground when the leak detection pump is turned ON and OFF using the tester.

Fig 21: Identifying ECM Connector

Result

RESULT TABLE

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

A: Go To Next Step

CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - ECM)

Turn the ignition switch OFF.
Disconnect the L4 canister connector.

Fig 22: Identifying L4 Canister Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Turn the ignition switch ON.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the Vacuum Pump.
Turn the leak detection pump ON.

Measure the voltage between terminal 1 of the canister connector and the body ground.

Result

RESULT TABLE

Test Results	Suspected Trouble Areas	Proceed to
Between 9 V and 14 V	Normal	A
Between 0 V and 3 V	Wire harness between ECM and leak detection pump	B

Reconnect the canister connector.

B: Go to step 32

A: Go To Next Step

CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - GROUND)

Disconnect the L4 canister connector.

Fig 23: Identifying L4 Canister Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Turn the ignition switch OFF.

Measure the resistance of the wire harness side connectors between terminal 6 of the canister connector and the body ground.

Result

RESULT TABLE

Test Results	Suspected Trouble Areas	Proceed to
Below 1 Ω	Leak detection pump	A
10 kΩ or higher	Wire harness between leak detection pump and body ground	B

Reconnect the canister connector.

A: Go to step 30

B: Go to step 32

INSPECT INTAKE MANIFOLD (EVAP PURGE PORT)

Turn the ignition switch OFF.
Disconnect the EVAP hose from the throttle body.
Start the engine.

Use your finger to confirm that the port of the throttle body has suction.

Result

RESULT TABLE

Test Results	Suspected Trouble Areas	Proceed to
Suction applied	EVAP hose between intake manifold and purge VSV	A
No suction	Intake manifold	B

A: Go to step 33

B: Go to step 34

CORRECTLY REINSTALL OR REPLACE FUEL CAP
HINT:
- When reinstalling the fuel cap, tighten it until a few click sounds are heard.
- When replacing the fuel cap, use a fuel cap that meets OEM specifications, and tighten it until a few click sounds are heard.
NEXT: Go to step 37
REPLACE FUEL CAP
HINT:

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

NEXT: Go to step 37
LOCATE EVAP LEAK
1. Reinstall the fuel cap.
2. Disconnect the vent hose.
  
  Fig 24: Identifying Canister, Fuel Cap And Vent Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the EVAP tester to the canister with the adapter.
  
  Fig 25: Connecting EVAP Tester To Canister With Adapter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28 mmHg).
5. Apply soapy water to the piping and connecting parts of the EVAP system.
6. Look for areas where bubbles appear. This indicates leak point.
7. 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 37
REPLACE CANISTER ASSEMBLY
1. Replace the canister assembly.
  NOTE: When replacing the canister, check the canister pump module interior and related pipes for water, fuel or 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.
NEXT: Go to step 37
REPLACE 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 hose.
NEXT: Go to step 37
REPAIR OR REPLACE HARNESS AND CONNECTOR
NEXT: Go to step 37
REPLACE EVAP HOSE (INTAKE MANIFOLD - PURGE VSV)
NEXT: Go to step 37
INSPECT INTAKE MANIFOLD (EVAP PURGE PORT)
1. Remove the throttle body (See REMOVAL ).
2. Check that the EVAP purge port of the intake manifold is not clogged. If necessary, replace the intake manifold.
NEXT: Go to step 37
REPLACE ECM
1. Replace the ECM (See REMOVAL ).
NEXT: Go to step 37
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 37
PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
NOTE:
- The Evaporative System Check (Automatic Mode) consists of five 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, making the leak check of the fuel tank 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 the DTCs (See DTC CHECK/CLEAR ).
2. Enter the following menus: Powertrain / Engine and ECT / Utility / Evaporative System Check / Automatic Mode.
3. After the System Check is completed, check for pending DTCs by entering the following menus: Powertrain / Engine and ECT / Trouble Codes / Pending.
  HINT:
  
  If no pending DTC is found, the repair has been successfully completed.
NEXT: COMPLETED