EVAP System: Procedure

WARNING: This page is about a different variant/trim than selected.

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 and turn the Techstream on.
6. Enter the following menus: Powertrain / Engine / 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.
  
  Fig 1: DTC Malfunctioning Areas Chart
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  If the reference pressure difference between the first and second checks is more than the specification, the DTCs relating to the reference pressure (P043E, P043F, P2401, P2402 and P2419) are stored.
NEXT: Go to next step
PERFORM EVAP SYSTEM CHECK (AUTOMATIC MODE)
NOTE:
- In the Evaporative System Check (Automatic Mode) a series of 5 steps is 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 unavailable.
- 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. Connect the Techstream to the DLC3.
2. Clear the DTCs, refer to DTC CHECK / CLEAR .
3. Enter the following menus: Powertrain / Engine / Utility / Evaporative System Check / Automatic Mode.
4. After the Evaporative System Check is completed, check for pending DTCs. Enter the following menus: Powertrain / Engine / Trouble Codes / Pending.
  HINT:
  
  If no pending DTC is displayed, perform the Monitor Confirmation after this repair is completed. After this confirmation, check for pending DTCs. If no DTC is displayed, the EVAP system is normal.
NEXT: Go to next step
PERFORM EVAP SYSTEM CHECK (MANUAL MODE)

Fig 2: Identifying EVAP System Check (Manual Mode) Graph
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- In the Evaporative System Check (Manual Mode), the series of 5 Evaporative System Check steps are performed 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, making the leak check of the fuel tank unavailable.
- 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. Connect the Techstream to the DLC3.
2. Clear the DTCs, refer to DTC CHECK / CLEAR .
3. Enter the following menus: Powertrain / Engine / Utility / Evaporative System Check / Manual Mode.
NEXT: Go to next step

PERFORM EVAP SYSTEM CHECK (STEP 1/5)

Fig 3: Identifying EVAP System Chart (Step 1/5)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 1/5.

Result

DTC*	Result	Suspected Trouble Area	Proceed to
-	Virtually no variation in EVAP pressure	Not yet determined	A
P0451	EVAP pressure fluctuates by +/-0.3 kPa-g (2.25 mmHg-g) or more	Pressure sensor noising	B

*: The DTCs relating to the EVAP system displayed on the Techstream when checking.

B → See step 30

A: Go to next step

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

Fig 4: Identifying EVAP System Chart (Step 1/5 To 2/5)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Result

DTC*	Result	Suspected Trouble Area	Proceed to
-	Virtually no variation in EVAP pressure during step 1/5. Then decreases to reference pressure standard*	Not yet determined	A
P2402	Small difference between EVAP pressures during steps 1/5 and 2/5	Vacuum pump stuck ON	B

*: The DTCs related to the EVAP system are displayed on the Techstream when checking.

HINT:

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

B → See step 23

A: Go to next step

PERFORM EVAP SYSTEM CHECK (STEP 2/5)

Fig 5: EVAP Pressure Malfunction Chart - 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*1 (Step "A").

Check the EVAP pressure again when it has stabilized. This pressure is the reference pressure standard (Step "B").

*1: The leak detection pump begins to operate at the time step 2/5 starts.

Result

DTC*2	Result	Suspected Trouble Area	Proceed to
-	EVAP pressure in step (B) is between -4.85 kPa-g and -1.06 kPa-g (-36.38 mmHg-g and -7.95 mmHg-g)	Not yet determined	A
P043F and P2401	EVAP pressure in step (B) is -1.06 kPa-g (-7.95 mmHg-g) or more	Reference orifice high-flow Leak detection pump stuck OFF	B
P043E	EVAP pressure in step (B) is less than -4.85 kPa-g (-36.38 mmHg-g)	Reference orifice clogged	C
P2419	EVAP pressure in step (A) is more than -1.06 kPa-g (-7.95 mmHg-g)	Vent valve stuck closed	D

*2: The DTCs related to the EVAP system are displayed on the Techstream when checking.

B → See step 11

C → See step 30

D → See step 19

A: Go to next step

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

Fig 6: EVAP Pressure Malfunction Chart - Step 2/5 To 3/5

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure increase in step 3/5.

Result

DTC*	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	A
P2420	No variation in EVAP pressure even after proceeding from step 2/5 to step 3/5	Vent valve stuck open (vent)	B
P0451	No variation in EVAP pressure during steps 1/5 through 3/5	Canister pressure sensor malfunction	C

*: The DTCs related to the EVAP system are displayed on the Techstream when checking.

B → See step 20

C → See step 30

A: Go to next step

PERFORM EVAP SYSTEM CHECK (STEP 3/5)

Fig 7: 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-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.
NEXT: Go to next step

PERFORM EVAP SYSTEM CHECK (STEP 4/5)

Fig 8: EVAP Pressure Malfunction Chart - Step 4/5

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 4/5.

Result

DTC*	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	A
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 EVAP hose between purge VSV and intake manifold	B
P0441	Variation in EVAP pressure is 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	C

*: The DTCs related to the EVAP system are displayed on the Techstream when checking.

B → See step 15

C → See step 12

A: Go to next step

PERFORM EVAP SYSTEM CHECK (STEP 5/5)

Fig 9: EVAP Pressure Malfunction Chart - 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 standard (step 5/5).

Result

DTC*	Result	Suspected Trouble Area	Proceed to
-	EVAP pressure (step 3/5) lower than second reference pressure standard (step 5/5)	Not yet determined (no leakage from EVAP system)	A
P0441 and P0455	EVAP pressure (step 3/5) higher than [second reference pressure standard (step 5/5) x 0.2]	Purge VSV stuck open EVAP gross leak	B
P0456	EVAP pressure (step 3/5) higher than second reference pressure standard (step 5/5)	EVAP small leak	B

*: The DTCs related to the EVAP system are displayed on the Techstream when checking.

A → See step 36

B → See step 12

PERFORM EVAP SYSTEM CHECK (STEP 3/5)

Fig 10: EVAP Pressure Malfunction Chart - Step 3/5

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the EVAP pressure in step 3/5.

Result

DTC*	Result	Suspected Trouble Area	Proceed to
P043F	EVAP pressure is less than [reference pressure standard] measured in step 2/5	Reference orifice high-flow	A
P2401	EVAP pressure is almost the same as [reference pressure standard] measured in step 2/5	Leak detection pump stuck OFF	B

*: The DTCs related to the EVAP system are displayed on the Techstream when checking.

HINT:

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

A → See step 30

B → See step 23

PERFORM ACTIVE TEST USING TECHSTREAM (PURGE VSV)

Enter the following menus: Powertrain / Engine / Active Test / Activate the VSV for EVAP Control.

Fig 11: Identifying Purge VSV
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Disconnect the hose (connected to the canister) from the purge VSV.
Start the engine.
Using the Techstream, turn off the purge VSV (EVAP VSV: OFF).
Confirm that the purge VSV has no suction with your fingers.
Using the Techstream, turn on the purge VSV (EVAP VSV: ON).

Confirm that the purge VSV has suction with your fingers.

Result

Result	Suspected Trouble Area	Proceed to
No suction when purge VSV turned OFF, and suction applied when turned ON	-	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

Reconnect the hose.

B → See step 14

C → See step 15

A: Go to next step

CHECK FUEL CAP ASSEMBLY

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

HINT:

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

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

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

Result

Test Result	Suspected Trouble Area	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 → See step 29

B → See step 27

C → See step 28

INSPECT PURGE VSV

Turn the ignition switch off.

Fig 12: Identifying Purge VSV And Purge VSV Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Disconnect the purge VSV connector.
Disconnect the hose (connected to the canister) from the purge VSV.
Start the engine.

Confirm that the purge VSV has no suction with your fingers.

Result

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

Reconnect the purge VSV connector.
Reconnect the hose.

A → See step 35

B → See 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
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Start the engine.

Confirm that the hose has suction with your fingers.

Result

Result	Suspected Trouble Area	Proceed to
Suction applied	-	A
No suction	Intake manifold EVAP hose between purge VSV and intake manifold	B

Reconnect the hose.

B → See step 26

A: Go to next step

INSPECT PURGE VSV

Remove the purge VSV.

Fig 14: Inspecting Vacuum Switching Valve No. 1 (Purge VSV)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply battery voltage to the terminals of the purge VSV.

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

Result

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

Install the purge VSV.

B → See step 31

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

Standard Voltage

Tester Connection	Switch Condition	Specified Condition
B29-1 - B29-2	Ignition switch ON	11 to 14 V

Result

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

Reconnect the purge VSV connector.

B → See step 32

A: Go to next step

CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM)

Disconnect the ECM connector and the purge VSV connector.

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

Standard Resistance

Tester Connection	Condition	Specified Condition
B51-26 (PRG) - B29-2	Always	Below 1 Ω
B51-26 (PRG) - Body ground	Always	10 kΩ or higher
B29-1 - Body ground	Always	10 kΩ or higher

Reconnect the purge VSV connector.
Reconnect the ECM connector.

OK → See step 35

NG → See step 32

PERFORM ACTIVE TEST USING TECHSTREAM (FOR VENT VALVE)

Turn the ignition switch to ON.

Fig 15: Identifying ECM Connector Terminals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Enter the following menus: Powertrain / Engine / Active Test / Activate the VSV for Vent Valve.

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

Standard Voltage

Tester Connection	Condition	Specified Condition
D61-7 (VPMP) - Body ground	Vent valve ON	11 to 14 V
D61-7 (VPMP) - Body ground	Vent valve OFF	Below 3 V

Result

Result	Suspected Trouble Area	Proceed to
Between 11 V and 14 V when OFF Below 3 V when ON	Vent valve	A
Below 3 V when OFF and ON	ECM	B

A → See step 22

B → See step 35

PERFORM ACTIVE TEST USING TECHSTREAM (FOR VENT VALVE)

Turn the ignition switch to ON.

Fig 16: Identifying ECM Connector Terminals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Enter the following menus: Powertrain / Engine / Active Test / Activate the VSV for Vent Valve.

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

Standard Voltage

Tester Connection	Condition	Specified Condition
D61-7 (VPMP) - Body ground	Vent valve ON	11 to 14 V
D61-7 (VPMP) - Body ground	Vent valve OFF	Below 3 V

Result

Result	Suspected Trouble Area	Proceed to
Below 3 V when OFF and ON	Power source of vent valve	A
Between 11 V and 14 V when OFF Below 3 V when ON	Vent valve	B
Between 11 V and 14 V when OFF and ON	ECM	C

B → See step 22

C → See step 35

A: Go to next step

INSPECT CANISTER PUMP MODULE (POWER SOURCE FOR VENT VALVE)

Turn the ignition switch off.

Fig 17: Identifying Canister Pump Module & Connector Terminals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Disconnect the canister pump module connector.
Turn the ignition switch to ON.

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

Standard Voltage

Tester Connection	Switch Condition	Specified Condition
N8-9 (VLVB) - Body ground	Ignition switch ON	11 to 14 V

Result

Test Result	Suspected Trouble Area	Proceed to
Between 11 V and 14 V	Vent valve ECM	A
Between 0 V and 3 V	Power source wire harness of vent valve	B

Reconnect the canister pump module connector.

B → See step 32

A: Go to next step

INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION)

Turn the ignition switch off.

Fig 18: Identifying Canister Pump Module & Connector Terminals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Disconnect the canister pump module connector.
Apply the battery voltage to terminals VLVB and VGND of the pump module.

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

Result

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

Reconnect the canister pump module connector.

A → See step 32

B → See step 30

PERFORM ACTIVE TEST USING TECHSTREAM (FOR CANISTER PUMP MODULE)

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

Fig 19: Identifying ECM Connector Terminals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard Voltage

Tester Connection	Condition	Specified Condition
D61-9 (MPMP) - Body ground	Leak detection pump ON (Active Test ON)	11 to 14 V

Result

Test Result	Suspected Trouble Area	Proceed to
Between 0 V and 3 V when OFF Between 11 V and 14 V when ON	-	A
Between 11 V and 14 V when OFF Between 0 V and 3 V when ON	ECM	B

B → See step 35

A: Go to next step

CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - ECM)

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

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

Standard Voltage

Tester Connection	Condition	Specified Condition
N8-1 (MTRB) - Body ground	Leak detection pump ON (Active Test ON)	11 to 14 V

Result

Test Result	Suspected Trouble Area	Proceed to
Between 11 V and 14 V	-	A
Between 0 V and 3 V	Wire harness between ECM and leak detection pump	B

Reconnect the canister pump module connector.

B → See step 32

A: Go to next step

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

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

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

Standard Resistance

Tester Connection	Condition	Specified Condition
N8-6 (MGND) - Body ground	Always	Below 1 Ω

Result

Test Result	Suspected Trouble Area	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 pump module connector.

A → See step 30

B → See step 32

INSPECT INTAKE MANIFOLD

Stop the engine.
Disconnect the EVAP hose from the intake manifold.
Start the engine.

Confirm that the port of the intake manifold has suction with your fingers.

Result

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

Reconnect the EVAP hose.

A → See step 33

B → See 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 → See step 37
REPLACE FUEL CAP ASSEMBLY
HINT:

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

NEXT → See step 37
LOCATE EVAP LEAK
1. Disconnect the vent hose.
  
  Fig 20: Identifying Canister Pump Module Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the EVAP pressure tester tool to the canister with the adapter.
  
  Fig 21: Connecting EVAP Pressure Tester Tool To Canister
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Pressurize the EVAP system by 3.2 to 3.7 kPa-g (24 to 28 mmHg-g).
4. Apply soapy water to the piping and the connecting parts of the EVAP system.
5. Look for areas where bubbles appear. This indicates a leak point.
6. Repair or replace the leak point.
NEXT → See step 37
REPLACE CHARCOAL CANISTER ASSEMBLY
1. Replace the charcoal canister assembly, refer to 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 parts: 1) the pipe from the air inlet port to the canister pump module; 2) the canister filter; 3) the fuel tank vent hose.
  
  Fig 22: Identifying Inspection Areas Of Canister Pump Module Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NEXT → See step 37
REPLACE PURGE VSV
1. Replace the purge VSV, refer to REMOVAL .
NEXT → See step 37
REPAIR OR REPLACE HARNESS OR CONNECTOR
NEXT → See step 37
REPLACE EVAP HOSE (INTAKE MANIFOLD - PURGE VSV)
NEXT → See step 37
INSPECT INTAKE MANIFOLD
1. Check that the EVAP purge port of the intake manifold is not clogged. If necessary, replace the intake manifold.
NEXT → See step 37
REPLACE ECM
1. Replace the ECM, refer to REMOVAL .
NEXT → See 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 next step
PERFORM EVAP SYSTEM CHECK (AUTOMATIC MODE)
NOTE:
- In the Evaporative System Check (Automatic Mode), the series of 5 Evaporative System Check steps are performed automatically. 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 unavailable.
- 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 an Evaporative System Check, keep the temperature below 35°C (95°F).
1. Clear the DTCs, refer to DTC CHECK / CLEAR .
2. On the Techstream, 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 DTC is found, the repair has been successfully completed.
NEXT → COMPLETED