Evaporative Emission (EVAP) Control System: Inspection

Visually check for loose connections, sharp bends or damage.

Visually check for deformation, Cracks or fuel leakage.

Check if the cap and/or gasket are deformed or damaged. If necessary, repair or replace the cap.

Fig 1: Inspecting Fuel Tank Cap

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Warm up the engine and stop the engine.

   Allow the engine to warm up to normal operating temperature.

2. Install a vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge line.
   Fig 2: Inspecting EVAP System Line

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Hand-held Tester:

   Forced driving of the VSV for the EVAP.

   1. Connect a hand-held tester to the DLC3.
   2. Start the engine.
   3. Push the hand-held tester main switch ON.
   4. Use the ACTIVE TEST mode on the hand-held tester to operate the VSV for the EVAP.
      Fig 3: Connecting Hand-Held Tester To DLC3

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. If you have no Hand-held Tester:

   Forced driving of the VSV for the EVAP.

   1. Disconnect the VSV connector for the EVAP.
   2. Connect the positive (+) and negative (-) leads from the battery to the VSV terminals for the EVAP.
   3. Start the engine.
      Fig 4: Connecting Positive (+) & Negative (-) Leads From Battery To VSV Terminals For EVAP

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check the vacuum at idle.
   1. Vacuum: Maintain at 0.368 - 19.713 in.Hg (5 - 268 in.Aq) for over 5 seconds 

   HINT:

   If the vacuum does not change, you can conclude that the hose connecting the VSV to the service port has come loose or is blocked, or the VSV is malfunctioning.

6. Hand-held Tester:

   Conclude forced driving of the VSV for the EVAP.

   1. Stop the engine.
   2. Disconnect the hand-held tester from the DLC3.
7. If you have no Hand-held Tester:

   Conclude forced driving of the VSV for the EVAP.

   1. Stop the engine.
   2. Disconnect the positive (+) and negative (-) leads from the battery from the VSV terminals for the EVAP.
   3. Connect the VSV connector for the EVAP.
8. Disconnect the vacuum gauge from the EVAP service port on the purge line.
9. Connect a pressure gauge to the EVAP service port on the purge line.
   Fig 5: Checking Vacuum At Idle

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Check the pressure.
    1. Close off the air drain hose at the marked position of the canister with a hose clipper or similar instrument.
       Fig 6: Closing Off Air Drain Hose With Hose Clipper

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Add the pressure (13.5 - 15.5 in.Aq) from the EVAP service port.
       1. Pressure: 2 minutes after the pressure is added, the gauge should be over 7.7 - 8.8 in.Aq. 

       HINT:

       If you can't add pressure, you can conclude that the hose connecting the VSV - canister - fuel tank has slipped off or the VSV is open.

       Fig 7: Adding Pressure From EVAP Service Port To Hose

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check if the pressure decreases when the fuel tank cap is removed while adding pressure.
    Fig 8: Checking Pressure While Removing Fuel Tank Cap
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    If the pressure does not decrease when the filler cap is removed, then you can conclude that the hose connecting the service port to the fuel tank is blocked, etc.

11. Disconnect the pressure gauge from the EVAP service port on the purge line.

1. Disconnect the EVAP line hose from the charcoal canister side and then pressurize and make the internal pressure in the fuel tank 4 kPa (41 gf/cm² , 0.58 psi).
Fig 9: Disconnecting EVAP Line Hose From Charcoal Canister Side
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that the internal pressure of the fuel tank can be hold for 1 minute.
3. Check the connected portions of each hose and pipe.
4. Check the installed parts on the fuel tank

   If there is no abnormality, replace the fuel tank and filler pipe.

5. Reconnect the EVAP line hose to the charcoal canister.

1. Disconnect the purge line hose and EVAP line hose from the charcoal canister.
Fig 10: Disconnecting Purge Line Hose & EVAP Line Hose From Charcoal Canister
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Plug the EVAP port with a cap.
3. Disconnect the air drain hose from the canister tank, and plug its.
4. Pressurize 4 kPa (41 gf/cm² , 0.58 psi) to the purge port and check that there is ventilation through the EVAP line hose.

   HINT:

   In the condition that the fuel is full, as the float value of the fill check valve is closed and has no ventilation, it is necessary to check the fuel amount (volume).

5. Check if there is any stuck in the vent line hose and EVAP line hose.

   If there is no stuck in hoses, replace the fuel cutoff valve and fill check valve.

6. Reconnect the purge line hose and EVAP line hose to the charcoal canister.
7. Reconnect the air drain hose to the canister tank.

1. Disconnect the air inlet line hose from the charcoal canister.
Fig 11: Disconnecting Air Inlet Line Hose From Charcoal Canister
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that there is ventilation in the air inlet line.
3. Reconnect the air inlet line hose to the charcoal canister.

1. Remove the luggage trim from body.
   Fig 12: Removing Charcoal Canister Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the charcoal canister assembly.
   1. Disconnect the purge line hose, EVAP line hose and air inlet line from the charcoal canister.
   2. Disconnect the vent line hose from the charcoal canister.

      Push the connector deep inside, pinch portion A, and pull out the connector.

   3. Disconnect the air drain hose from the canister tank.
   4. Remove the 8 nuts and the charcoal canister assembly with protector.
   5. Disconnect the vapor pressure sensor connector.
   6. Disconnect the VSV connector for vapor pressure sensor.
   7. Remove the 2 bolts, nut and the charcoal canister assembly from the protector.

1. Visually check the charcoal canister for cracks or damage.
   Fig 13: Checking Charcoal Canister For Cracks Or Damage

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect the charcoal canister operation.
   1. Plug the vent port with a cap.
   2. While holding the purge port closed, blow air (1.76 kPa, 18 gf/cm² . 0.26 psi) into the EVAP port and check that air flows from the air drain port.
      Fig 14: Inspecting Charcoal Canister Operation (1 Of 4)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. While holding the purge port and the air drain port closed, blow air (1.76 kPa, 18 gf/cm² , 0.26 psi) into the EVAP port and check that air does not flow from the air inlet port.
      Fig 15: Inspecting Charcoal Canister Operation (2 Of 4)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Apply vacuum (3.43 kPa, 25.7 mmHg, 1.01 in.Hg) to the purge port, check that the vacuum does not decrease when the air inlet port is closed, and check that the vacuum decreases when the air inlet port is released.
      Fig 16: Inspecting Charcoal Canister Operation (3 Of 4)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. While holding the air inlet port closed, apply vacuum (3.43 kPa, 25.7 mmHg, 1.01 in.Hg) to the EVAP port and check that air flows into the purge port.

   If operation is not as specified, replace the charcoal canister.

Fig 17: Inspecting Charcoal Canister Operation (4 Of 4)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002