LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2020 >> Highlander L, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 40 (Engine Control System (T24A-FTS) - Diagnostic Codes (05 Of 11)) >> SFI System >> DTC P0441-9C: Evaporative Emission System Incorrect Purge Flow Low/Insufficient Flow [10/2022 - ] >> Procedure

DTC P0441-9C: Evaporative Emission System Incorrect Purge Flow Low/Insufficient Flow [10/2022 - ]: Procedure

WARNING: This page is about a different car, the 2025 Toyota Highlander, 2024 Toyota Highlander, and 2023 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
  1. PERFORM ACTIVE TEST USING GTS (ACTIVATE THE EVAP PURGE VSV) 
    GTY1106413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *1 Purge VSV
    *2 Fuel Vapor Feed Hose
    (to Canister)
    1. Disconnect the fuel vapor feed hose (connected to the canister) from the purge VSV.
    2. Start the engine.
    3. Using the GTS, turn on the purge VSV (Activate the EVAP Purge VSV: ON).

      Powertrain > Engine > Active Test 

      Tester Display
      Activate the EVAP Purge VSV
    4. Use your finger to confirm that the purge VSV has suction.

      Result

      Test Result Suspected Trouble Area Proceed to
      Suction applied
      • Problems with EVAP hose between canister and purge VSV
      • Canister (charcoal filter inside canister) clogged
      		 A
      No suction
      • Purge VSV stuck closed
      • No. 1 check valve stuck closed
      • Problems with EVAP hose between purge VSV and intake manifold
      • ECM
      		 B

    Result: 

    B 

    See step  9

    Result: 

    A 

    See step  2

  2. INSPECT EVAP HOSE (PURGE VSV - CANISTER) 
    1. Check for blockages in the EVAP purge line between the purge VSV and canister.

      OK

      No blockages in the EVAP purge line between the purge VSV and canister.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    See step  8

    Result: 

    OK 

    See step  3

  3. INSPECT CANISTER (CHARCOAL FILTER INSIDE CANISTER) 
    1. Check for filter blockage in the canister.

      Refer to PROCEDURE - Step 1

      OK

      No blockages in the canister.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    See step  7

    Result: 

    OK 

    See step  4

  4. INSPECT NO. 2 CHARCOAL CANISTER FILTER (CHARCOAL FILTER INSIDE CANISTER) 
    1. Check for filter blockage in the No. 2 Charcoal Canister Filter.

      Refer to PROCEDURE - Step 2

      OK

      No blockages in the No. 2 Charcoal Canister Filter.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    See step  6

    Result: 

    OK 

    See step  5

  5. REPLACE CANISTER PUMP MODULE 
    1. Replace the canister pump module.

      Refer to REMOVAL [10/2022 - ]

      NOTE:
      • When replacing the canister pump module, check the canister pump module interior, canister interior and related pipes for water, fuel and 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 sub-assembly. If liquids are present in the canister interior, replace the canister and canister pump module together.
      • Check for filter blockage in the canister. If the charcoal filter inside the canister is clogged, replace the canister and canister pump module together.
      • Check for filter blockage in the canister filter. If the canister filter has blockages, replace the canister filter.
      GTY1106414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Tank Vent Hose Sub-assembly *2 Canister
      *3 Canister Filter *4 Canister Pump Module
      *5 No. 2 Charcoal Canister Filter *6 Vent Hose
      *7 Air Inlet Port *8 Fuel Tank Cap
      *9 Fuel Tank - -
      *a Inspection Area
      (check for disconnection and/or cracks)      		 - -

      Result

      Proceed to
      NEXT

    Result: 

    NEXT 

    See step  25

  6. REPLACE NO. 2 CHARCOAL CANISTER FILTER 
    1. Replace the No. 2 charcoal canister filter.

      Refer to REMOVAL [10/2022 - ]

      NOTE:
      • When replacing the No. 2 charcoal canister filter, check the canister interior, 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: 1) the pipe from the air inlet port to the canister pump module; 2) the canister filter; and 3) the fuel tank vent hose sub-assembly.
      • Check for filter blockage in the canister filter. If the canister filter has blockages, replace the canister filter.
      GTY1106414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Tank Vent Hose Sub-assembly *2 Canister
      *3 Canister Filter *4 Canister Pump Module
      *5 No. 2 Charcoal Canister Filter *6 Vent Hose
      *7 Air Inlet Port *8 Fuel Tank Cap
      *9 Fuel Tank - -
      *a Inspection Area
      (check for disconnection and/or cracks)      		 - -

      Result

      Proceed to
      NEXT

    Result: 

    NEXT 

    See step  25

  7. REPLACE CANISTER 
    1. Replace the canister.

      Refer to REMOVAL [10/2022 - ]

      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: 1) the pipe from the air inlet port to the canister pump module; 2) the canister filter; and 3) the fuel tank vent hose sub-assembly.
      • Check for filter blockage in the canister filter. If the canister filter has blockages, replace the canister filter.
      GTY1106414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Tank Vent Hose Sub-assembly *2 Canister
      *3 Canister Filter *4 Canister Pump Module
      *5 No. 2 Charcoal Canister Filter *6 Vent Hose
      *7 Air Inlet Port *8 Fuel Tank Cap
      *9 Fuel Tank - -
      *a Inspection Area
      (check for disconnection and/or cracks)      		 - -

      Result

      Proceed to
      NEXT

    Result: 

    NEXT 

    See step  25

  8. REPAIR OR REPLACE EVAP PURGE LINE (PURGE VSV - CANISTER) 

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    See step  25

  9. INSPECT EVAP HOSE (PURGE VSV - INTAKE MANIFOLD) 
    GTY1105388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *1 Purge VSV
    *2 Fuel Vapor Feed Hose
    (to intake manifold)
    1. Disconnect the fuel vapor feed hose (connected to the intake manifold) from the purge VSV.
    2. Start the engine.
    3. Use your finger to confirm that the fuel vapor feed hose has suction.

      Result

      Test Result Suspected Trouble Area Proceed to
      Suction applied EVAP hose between purge VSV and intake manifold normal
      • Purge VSV
      • Purge VSV power source
      • Wire harness or connector between purge VSV and ECM
      • ECM
      		 A
      No suction
      • No. 1 check valve
      • Intake manifold port
      • EVAP hose between purge VSV and intake manifold
      		 B

    Result: 

    B 

    See step  20

    Result: 

    A 

    See step  10

  10. INSPECT PURGE VSV 
    GTY1077063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *1 Purge VSV
    1. Remove the purge VSV.
    2. Apply battery voltage to the terminals of the purge VSV.
    3. Confirm that air flows from port E to port F.

      Result

      Test Result Condition Suspected Trouble Area Proceed to
      Air flows Battery voltage is applied to purge VSV terminals Purge VSV normal
      • Purge VSV power source
      • Wire harness or connector between purge VSV and ECM
      • ECM
      		 A
      No air flow Battery voltage is applied to purge VSV terminals Purge VSV B

    Result: 

    B 

    See step  19

    Result: 

    A 

    See step  11

  11. CHECK TERMINAL VOLTAGE (POWER SOURCE OF PURGE VSV) 
    1. Disconnect the purge VSV connector.
    2. Turn the ignition switch to ON.
    3. Measure the voltage according to the value(s) in the table below.

      Result

      Tester Connection Condition Specified Condition Suspected Trouble Area Proceed to
      C32-1 (+B) - Body ground Ignition switch ON 11 to 14 V Purge VSV power source normal
      • Wire harness or connector between purge VSV and ECM
      		 A
      Other than result above Wire harness or connectors between purge VSV and battery B

    Result: 

    B 

    See step  14

    Result: 

    A 

    See step  12

  12. CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM) 
    1. Disconnect the purge VSV connector.
    2. Disconnect the ECM connector.
    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      C32-2 (EVP1) - C89-16 (PRG) Always Below 1 Ω
      C32-2 (EVP1) or C89-16 (PRG) - Body ground and other terminals Always 10 kΩ or higher

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    See step  18

    Result: 

    OK 

    See step  13

  13. REPLACE ECM 
    1. Replace the ECM.

      Refer to REMOVAL [10/2022 - 11/2023] , or refer to REMOVAL [11/2023 - ]

      Result

      Proceed to
      NEXT

    Result: 

    NEXT 

    See step  25

  14. INSPECT EFI-MAIN NO. 3 RELAY 
    1. Inspect the EFI-MAIN NO. 3 relay.

      Refer to PROCEDURE - Step 5 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 5 [11/2023 - ]

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPLACE EFI-MAIN NO. 3 RELAY 

    Result: 

    OK 

    See step  15

  15. CHECK TERMINAL VOLTAGE (POWER SOURCE OF EFI-MAIN NO. 3 RELAY) 
    1. Remove the EFI-MAIN NO. 3 relay from the No. 1 engine room relay block and No. 1 junction block assembly.
    2. Measure the voltage according to the value(s) in the table below.
      GTY1249861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly
      *2 EFI-MAIN NO. 3 relay

      Standard Voltage

      Tester Connection Condition Specified Condition
      3 (EFI-MAIN NO. 3 relay) - Body ground Always 11 to 14 V

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR (BATTERY - EFI-MAIN NO. 3 RELAY) 

    Result: 

    OK 

    See step  16

  16. CHECK HARNESS AND CONNECTOR (EFI-MAIN NO. 3 RELAY - BODY GROUND) 
    1. Remove the EFI-MAIN NO. 3 relay from the No. 1 engine room relay block and No. 1 junction block assembly.
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      1 (EFI-MAIN NO. 3 relay) - Body ground Always Below 1 Ω

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    See step  18

    Result: 

    OK 

    See step  17

  17. CHECK HARNESS AND CONNECTOR (EFI-MAIN NO. 3 RELAY - PURGE VSV) 
    1. Remove the EFI-MAIN NO. 3 relay from the No. 1 engine room relay block and No. 1 junction block assembly.
    2. Disconnect the purge VSV connector.
    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      5 (EFI-MAIN NO. 3 relay) - C32-1 (+B) Always Below 1 Ω
      5 (EFI-MAIN NO. 3 relay) or C32-1 (+B) - Body ground and other terminals Always 10 kΩ or higher

      Result

      Proceed to
      OK
      NG

    Result: 

    OK 

    REPAIR OR REPLACE HARNESS OR CONNECTOR (EFI-MAIN NO. 1 RELAY - EFI-MAIN NO. 3 RELAY) 

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

  18. REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    See step  25

  19. REPLACE PURGE VSV 
    1. Replace the purge VSV.

      Refer to REMOVAL [10/2022 - ]

      Result

      Proceed to
      NEXT

    Result: 

    NEXT 

    See step  25

  20. INSPECT NO. 1 CHECK VALVE 
    1. Inspect the No. 1 check valve.

      Refer to PROCEDURE - Step 2

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    See step  24

    Result: 

    OK 

    See step  21

  21. INSPECT INTAKE MANIFOLD (EVAP PURGE PORT) 
    1. Stop the engine.
    2. Disconnect the EVAP hose from the intake manifold.
    3. Start the engine.
    4. Use your finger to confirm that the port of the intake manifold has suction.

      Result

      Tester Connection Suspected Trouble Area Proceed to
      Suction applied EVAP hose between intake manifold and purge VSV A
      No suction Intake manifold (upper intake manifold) B

    Result: 

    B 

    See step  23

    Result: 

    A 

    See step  22

  22. REPAIR OR REPLACE EVAP PURGE LINE (INTAKE MANIFOLD - PURGE VSV) 

    Result

    Proceed to
    NEXT

    Result: 

    NEXT 

    See step  25

  23. INSPECT INTAKE MANIFOLD (EVAP PURGE PORT) 
    1. Check that the EVAP purge port of the intake manifold is not clogged. If necessary, replace the intake manifold.

      Refer to REMOVAL [10/2022 - ]

      Result

      Proceed to
      NEXT

    Result: 

    NEXT 

    See step  25

  24. REPLACE NO. 1 CHECK VALVE 
    1. Replace the No. 1 check valve.

      Refer to REMOVAL [10/2022 - ]

      Result

      Proceed to
      NEXT

    Result: 

    NEXT 

    See step  25

  25. CHECK WHETHER DTC OUTPUT RECURS (DTC P0441-9C) 
    1. Clear the DTCs.

      Powertrain > Engine > Clear DTCs 

    2. Turn the ignition switch off and wait for at least 30 seconds.
    3. Start the engine.
    4. Drive the vehicle in accordance with the driving pattern described in Confirmation Driving Pattern.
    5. Check the DTC judgment result.

      Powertrain > Engine > Utility 

      Tester Display
      All Readiness
    6. Input the DTC: P0441-9C.
      GTS Display Description
      NORMAL
      • DTC judgment completed
      • System normal
      ABNORMAL
      • DTC judgment completed
      • System abnormal
      INCOMPLETE
      • DTC judgment not completed
      • Perform driving pattern after confirming DTC enabling conditions

      Result

      Proceed to
      NEXT

    Result: 

    NEXT 

    END 

scientia non olet · About LEMON Manuals