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Home >> Toyota >> 2004 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine Control System (SFI) - Diagnostics (2AZ-FE)) >> EVAP Inspection Procedure >> Inspection Procedure

Inspection Procedure

WARNING: This page is about a different variant/trim than selected.
NOTE:
  • When a vehicle is brought into the workshop, leave it as is. Do not change the vehicle condition.
  • For example, do not tighten the fuel cap. Do not disassemble the pump module.
  1. CONFIRM DTC 
    1. Turn the ignition switch OFF and wait 10 seconds.
    2. Turn the ignition switch ON.
    3. Turn the ignition switch OFF and wait 10 seconds.
    4. Connect the hand-held tester to the DLC3.
    5. Turn the ignition switch ON and press the hand-held tester switch ON.
    6. Enter the following menus: DIAGNOSIS/ENHANCED OBD II/DTC INFO/CURRENT CODES.
    7. Confirm the DTCs and freeze frame data.

      If the EVAP system's DTCs are set, the malfunctioning area can be determined with the table below.

      8. Fig 1: EVAP DTC'S Malfunctioning Area Determining Chart
      G02908073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. NEXT: GO TO NEXT STEP. 
  2. PERFORM EVAP SYSTEM CHECK (AUTO OPERATION) 
    NOTE:
    • In the EVAP SYSTEM CHECK (AUTO OPERATION), 6 series of EVAP SYSTEM CHECK steps are performed automatically. It takes approximately 15 minutes maximum.
    • 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 the leak check of the fuel tank is unavailable.
    • Do not run the engine.
    • When the temperature of the fuel is 35 C(95 F) or more, a large amount of vapors form and any check results become inaccurate. When performing an EVAP SYSTEM CHECK, keep the temperature below 35°C(95°F).
    1. Clear the DTC with the hand-held tester.
    2. Enter the following menus: DIAGNOSIS/ENHANCED OBDII/SYSTEM CHECK/EVAP SYS CHECK/AUTO OPERATION.
    3. After the EVAP SYSTEM CHECK is completed, check for pending DTC. Enter the following menus: DIAGNOSIS/ENHANCED OBDII/DTC INFO/PENDING DTC.
    1. NEXT: GO TO NEXT STEP. 
  3. PERFORM EVAP SYSTEM CHECK (MANUAL OPERATION) 
    Fig 2: EVAP System Check (Manual Operation)
    G02908074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • In the EVAP SYSTEM CHECK (MANUAL OPERATION), 6 series of 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 and the leak check of the fuel tank is unavailable.
    • Do not run the engine.
    • When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapors form and any check results become inaccurate. When performing an EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F).
    1. Clear the DTC with the hand-held tester.
    2. Enter the following menus: DIAGNOSIS/ENHANCED OBDII/SYSTEM CHECK/EVAP SYS CHECK/MANUAL OPERATION.
    1. NEXT: GO TO NEXT STEP. 
  4. PERFORM EVAP SYSTEM CHECK (STEP 1/6 - 2/6) 
    Fig 3: EVAP System Check (Step 1/6 - 2/6)
    G02908075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Check the EVAP pressure from step 1/6 to 2/6.

    Fig 4: EVAP Pressure Result Chart (Step 1/6 - 2/6)
    G02908076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. B: Go to step   22 . 
    2. C: Go to step   29 . 
    3. A: GO TO NEXT STEP. 
  5. PERFORM EVAP SYSTEM CHECK (STEP 3/6) 
    Fig 5: EVAP System Check (Step 3/6)
    G02908077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Proceed to step 3/6. 60 seconds later, check the EVAP pressure.
    2. Make a note of the 0.02 inch leak pressure.
      Fig 6: EVAP Pressure Result Chart (Step 3/6)
      G02908078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. B: Go to step   10 . 
    2. C: Go to step   29 . 
    3. D: Go to step   18 . 
    4. A: GO TO NEXT STEP. 
  6. PERFORM EVAP SYSTEM CHECK (STEP 3/6 - 4/6) 
    Fig 7: EVAP System Check (Step 3/6 - 4/6)
    G02908079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Proceed to step 4/6. Check the EVAP pressure increase.

    Fig 8: EVAP Pressure Result Chart (Step 3/6 - 4/6)
    G02908080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. B: Go to step   19 . 
    2. C: Go to step   29 . 
    3. A: GO TO NEXT STEP. 
  7. PERFORM EVAP SYSTEM CHECK (STEP 4/6) 
    Fig 9: EVAP System Check Graphical Representation (Step 4/6)
    G02908081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Wait until the EVAP pressure change is less than 0.75 mmHg (0.1 kPa) for 30 seconds.
    2. Measure the EVAP pressure.

      HINT:

      A few minutes are required for the EVAP pressure to be saturated. When fuel in the fuel tank is little, it takes maximum 12 minutes.

      Fig 10: EVAP Pressure Result Chart
      G02908082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. NG: Go to step   11 . 
    2. OK: GO TO NEXT STEP. 
  8. PERFORM EVAP SYSTEM CHECK (STEP 4/6 - 5/6) 
    Fig 11: EVAP System Check (Step 4/6 - 5/6)
    G02908083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Proceed to 5/6 and check the EVAP pressure.

    Fig 12: EVAP Pressure Result Chart (Step 5/6)
    G02908084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. NG: Go to step   29 . 
    2. OK: GO TO NEXT STEP. 
  9. PERFORM EVAP SYSTEM CHECK (STEP 5/6 - 6/6) 
    Fig 13: EVAP System Check (Step 5/6 - 6/6)
    G02908085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Proceed to 6/6 and check the EVAP pressure.

    Fig 14: EVAP Pressure Result Chart (Step 6/6)
    G02908086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. A: Go to step   35 . 
    2. B: Go to step   14 . 
    3. C: Go to step   11 . 
    4. OK: GO TO NEXT STEP. 
  10. PERFORM EVAP SYSTEM CHECK (STEP 4/6) 
    Fig 15: EVAP System Check (Step 4/6)
    G02908087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Proceed to step 4/6. Check the EVAP pressure.

    Fig 16: EVAP Pressure Result Chart (Step 4/6)
    G02908088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. A: Go to step   29 . 
    2. B: Go to step   22 . 
  11. PERFORM ACTIVE TEST (PURGE VSV) 
    1. Finish the system check.
    2. Disconnect the hose (to canister) from the purge VSV.
    3. Start the engine.
    4. Enter the following menus: ACTIVE TEST/EVAP VSV (ALONE) on the hand-held tester.
    5. Turn the purge VSV OFF (EVAP VSV: OFF).
    6. Use your finger and confirm that the purge VSV has no suction.
    7. Turn the purge VSV ON (EVAP VSV: ON).
    8. Use your finger and confirm that the purge VSV has suction.
      Fig 17: Disconnecting Hose From Purge VSV
      G02908089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 18: Active Test Result Chart (Purge VSV)
      G02908090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. B: Go to step   13 . 
    2. C: Go to step   14 . 
    3. A: GO TO NEXT STEP. 
  12. CHECK FUEL CAP 
    1. Check if the fuel cap is tightened until a few "click" sounds are heard.
    2. If you have the EVAP tester, check the fuel cap using the fuel cap adaptor.
      1. Install the fuel cap to the fuel cap adaptor, and connect the hose from the EVAP tester's pump.
      2. Pressurize the fuel cap adaptor 24-28 mmHg or 45 seconds.
      3. Stop the pump and seal the fuel cap adaptor.
      4. Wait 2 minutes.
      5. Confirm that the pressure is higher than 15 mmHg.

      If the pressure is higher than 15 mmHg, the fuel cap is normal.

      If the pressure is less than 15 mmHg, the fuel cap is malfunctioning.

      FUEL CAP TEST RESULT

      Result Proceed to
      Fuel cap is normal. A
      Fuel cap is loose. B
      No fuel cap, fuel cap is malfunctioning or fuel cap does not meet OEM specification. C
    1. A: Go to step   28 . 
    2. B: Go to step   26 . 
    3. C: Go to step   27 . 
  13. INSPECT PURGE VSV 
    1. Turn the ignition switch OFF.
    2. Disconnect the purge VSV connector.
    3. Start the engine.
    4. Use your finger and confirm that the purge VSV has no suction.
      5. Fig 19: Locating Purge VSV Connector
      G02908091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 20: Purge VSV Test Result Chart
      G02908092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. OK: Go to step   34 . 
    2. NG: Go to step   30 . 
  14. CHECK EVAP HOSE (PURGE VSV - THROTTLE BODY) 
    1. Disconnect the hose (to throttle body) from the purge VSV.
    2. Start the engine.
    3. Use your finger and confirm that the purge VSV has suction.
      4. Fig 21: Disconnecting Throttle Body Hose From Purge VSV
      G02908093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 22: Purge VSV - Throttle Body Test Result Chart
      G02908094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. NG: Go to step   25 . 
    2. OK: GO TO NEXT STEP. 
  15. INSPECT PURGE VSV 
    1. Remove the purge VSV.
    2. Apply battery voltage to the purge VSV.
    3. Using an air gun, confirm that air flows from A to B as shown in the illustration.
      4. Fig 23: Applying Battery Voltage To Purge VSV
      G02908095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 24: Purge VSV Test Result Chart
      G02908096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. NG: Go to step   30 . 
    2. OK: GO TO NEXT STEP. 
  16. CHECK WIRE 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.
      4. Fig 25: Identifying V4 Purge VSV Connector Terminals
      G02908097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 26: V4 Purge VSV Test Result Chart
      G02908098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. NG: Go to step   31 . 
    2. OK: GO TO NEXT STEP. 
  17. CHECK WIRE HARNESS AND CONNECTOR (PURGE VSV - ECM) 
    1. Disconnect the E7 connector and the V4 purge VSV connector.
    2. Measure the resistance between the E7 and V4 connecters.
      Fig 27: Identifying E7 ECM Connector Resistance Test Terminals
      G02908099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 28: Identifying V4 Purge VSV Connector Terminals
      G02908100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard: 

      TESTER CONNECTION AND CONDITION SPECIFICATIONS

      Tester Connection Specified Condition
      E7-34 (PRG) - V4-2 10 Ω or less
      E7-34 (PRG) - Body ground 10 kΩ or more
      V4-2 - Body ground 10 kΩ or more
    1. OK: Go to step   34 . 
    2. NG: Go to step   31 . 
  18. CHECK ECM (FOR VENT VALVE) 
    1. Finish the system check.
    2. Turn the ignition switch ON.
    3. Enter the following menus: ACTIVE TEST/VENT VALVE (ALONE) on the hand-held tester.
    4. Operates the vent valve (ON/OFF) and measure the voltage between E5-27 (VPMP) of the ECM terminal and the body ground.
      5. Fig 29: Identifying E5 ECM Connector Voltage Test Terminal
      G02908101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 30: ECM Test Result Chart
      G02908102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. A: Go to step   21 . 
    2. B: Go to step   34 . 
  19. CHECK ECM (FOR VENT VALVE) 
    1. Finish the system check.
    2. Turn the ignition switch ON.
    3. Enter the following menus: ACTIVE TEST/VENT VALVE (ALONE) on the hand-held tester.
    4. Operates the vent valve (ON/OFF) and measure the voltage between E5-27 (VPMP) of the ECM terminal and the body ground.
      5. Fig 31: Identifying E5 ECM Connector Voltage Test Terminal
      G02908103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 32: ECM Test Result Chart
      G02908104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. B: Go to step   21 . 
    2. C: Go to step   34 . 
    3. A: GO TO NEXT STEP. 
  20. CHECK POWER SOURCE (FOR VENT VALVE) 
    1. Turn the ignition switch OFF.
    2. Remove the exhaust tail pipe and the heat insulator under the canister.
    3. Disconnect the C17 canister connector.
    4. Turn the ignition switch ON.
    5. Measure the voltage between terminal 9 of the C17 connector and the body ground.
      6. Fig 33: Locating C17 Canister Connector
      G02908105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 34: Identifying C17 Canister Connector Terminals
      G02908106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 35: Vent Valve Test Result Chart
      G02908107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. NG: Go to step   31 . 
    2. OK: GO TO NEXT STEP. 
  21. INSPECT VENT VALVE 
    1. Turn the ignition switch OFF.
    2. Apply the positive battery voltage to terminal 9 of the pump module and the negative battery voltage to terminal 8 of the pump module.
    3. Touch the pump module to confirm the vent valve operation.
      4. Fig 36: Inspecting Vent Valve Operation (Energized)
      G02908108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 37: Vent Valve Test Result Chart
      G02908109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. OK: Go to step   31 . 
    2. NG: Go to step   29 . 
  22. CHECK ECM (FOR VACUUM PUMP) 
    1. Proceed to step 7/6 and finish the system check.
    2. Enter the following menus: ACTIVE TEST/VCUMM PUMP (ALONE) on the hand-held tester.
    3. Measure the voltage between E5-4 (MPMP) of the ECM terminal and the body ground when operating the vacuum pump with the tester.
      4. Fig 38: Identifying E5 ECM Connector Voltage Test Terminals
      G02908110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 39: Vacuum Pump Test Result Chart
      G02908111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. NG: Go to step   34 . 
    2. OK: GO TO NEXT STEP. 
  23. CHECK WIRE HARNESS AND CONNECTOR (VACUUM PUMP - ECM) 
    1. Turn the ignition switch OFF.
    2. Remove the exhaust tail pipe and the heat insulator under the canister.
    3. Disconnect the C17 canister connector.
    4. Turn the ignition switch ON.
    5. Enter the following menus: ACTIVE TEST/VCUMM PUMP (ALONE) on the hand-held tester.
    6. Turn the vacuum pump ON with the tester.
    7. Measure the voltage between the terminal C17-1 and the body ground.
      8. Fig 40: Locating C17 Canister Connector
      G02908112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 41: Identifying C17 Canister Connector Terminals
      G02908113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 42: Vacuum Pump ECM Test Result Chart
      G02908114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. NG: Go to step   31 . 
    2. OK: GO TO NEXT STEP. 
  24. CHECK WIRE HARNESS AND CONNECTOR (VACUUM PUMP - GROUND) 
    1. Turn the ignition switch OFF.
    2. Measure the resistance between the terminal C17-6 and the body ground.
      3. Fig 43: Identifying C17 Canister Connector Terminals
      G02908115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 44: Vacuum Pump - Ground Test Result Chart
      G02908116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. OK: Go to step   29 . 
    2. NG: Go to step   31 . 
  25. CHECK THROTTLE BODY 
    1. Stop the engine.
    2. Disconnect the EVAP hose from the throttle body.
    3. Start the engine.
    4. Use your finger and confirm that the throttle body has suction.
      5. Fig 45: Throttle Body Test Result Chart
      G02908117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. OK: Go to step   32 . 
    2. NG: Go to step   33 . 
  26. TIGHTEN FUEL CAP 

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

    1. NEXT: Go to step   36 . 
  27. REPLACE FUEL CAP 

    Install a new fuel cap and tighten it until a few "click" sounds are heard.

    1. NEXT: Go to step   36 . 
  28. REPAIR EVAP LEAK 
    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 (SST) to close the canister's passage to air.

      SST 00002-6872A

      5. Fig 46: Pinching Pump Module Atmospheric Side Hose
      G02908118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the pressure gauge (SST) to the service port (green cap near the air cleaner box).
    6. Pressurize the EVAP system until 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.
      9. Fig 47: Connecting Pressure Gauge To Service Port
      G02908119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. NEXT: Go to step   36 . 
  29. REPLACE PUMP MODULE 
    1. Remove the exhaust tail pipe.
    2. Remove the heat insulator under the canister.
    3. Disconnect the hoses and the connector.
    4. Remove the 3 bolts and the pump module with the O-ring.
    5. Install a new pump module with a new O-ring.
    6. Install the 3 bolts.
    7. Connect the hoses and the connector.
    8. Go to the next step before installing the exhaust tail pipe.
      9. Fig 48: Identifying Pump Module
      G02908120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. NEXT: Go to step   36 . 
  30. REPLACE PURGE VSV 
    1. Disconnect the connector and the hoses
    2. Remove the purge VSV.
    3. Install a new one.
    4. Connect the connector and the hoses.
      5. Fig 49: Locating Purge VSV
      G02908121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. NEXT: Go to step   36 . 
  31. REPAIR OR REPLACE WIRE HARNESS AND CONNECTOR 

    In case that the exhaust tail pipe is removed, go to the next step before installing it.

    1. NEXT: Go to step   36 . 
  32. REPLACE EVAP HOSE (THROTTLE BODY - PURGE VSV) 
    1. NEXT: Go to step   36 . 
  33. CHECK THROTTLE BODY 
    1. Remove the throttle body (See REPLACEMENT ).
    2. Check that there is no clog in the EVAP purge port of the throttle body. If necessary, replace the throttle body.
    1. NEXT: Go to step   36 . 
  34. REPLACE ECM (See  REPLACEMENT  ) 
    1. NEXT: Go to step   36 . 
  35. REPAIR PTC PART 

    Repair the malfunctioning area indicated by the confirmed DTCs when the vehicle was brought in.

    1. NEXT: Go to step   36 . 
  36. PERFORM EVAP SYSTEM CHECK (AUTO OPERATION) 
    NOTE:
    • In the EVAP SYSTEM CHECK (AUTO OPERATION), 6 series of EVAP SYSTEM CHECK steps are performed automatically. It takes approximately 15 minutes maximum.
    • 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 the leak check of the fuel tank is unavailable.
    • Do not run the engine.
    • When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapors form and any check results become inaccurate. When performing an EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F).
    1. Clear the DTC with the hand-held tester.
    2. Enter the following menus: DIAGNOSIS/ENHANCED OBDII/SYSTEM CHECK/EVAP SYS CHECK/AUTO OPERATION.
    3. After the EVAP SYSTEM CHECK is complete, check for pending DTCs.
    4. If no pending DTC is displayed, the repair has been completed properly.
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