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Engine Controls - System & Component Testing - V6 & V8: Diagnosis Toyota Sequoia I

Testing & Diagnostics 19 illustrations ~6952 words

Fuel EVAP System Test (Avalon, Camry Solara & Sienna)

Note. Manufacturer provides testing information for testing airtightness of fuel tank and components along with testing of charcoal canister and fuel EVAP system.

Scheme 81

Scheme 81: Fuel EVAP System Test (Avalon, Camry Solara & Sienna)
Scheme 81: Fuel EVAP System Test (Avalon, Camry Solara & Sienna)

Scheme 82

Scheme 82
Scheme 82

Scheme 83

Scheme 83
Scheme 83

Scheme 84

Scheme 84
Scheme 84
  1. Inspect all fuel EVAP system lines and connections for sharp bends or damage. Fuel inlet pipe may also be referred to as fuel filler pipe. Inspect fuel inlet pipe for cracks, damage or fuel leakage. Inspect fuel tank cap for cracks or deformed gasket. Replace components if defective or damaged.
  2. Start engine. Warm engine to normal operating temperature. Shut engine off. Connect vacuum gauge from EVAP System Test Kit (00002-6872A) to EVAP service port. EVAP service port is located in engine compartment, in the purge vacuum hose for EVAP system. see scheme 161, see scheme 163 and see scheme 167.
  3. Operate EVAP Vacuum Switching Valve (VSV). If Toyota hand-held tester is available to operate EVAP VSV, go to next step. If Toyota hand-held tester is not available to operate EVAP VSV, go to step 5.
  4. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. see scheme 23, see scheme 25 and see scheme 29. Start engine. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, activate EVAP VSV. Go to step 6.
  5. Disconnect electrical connector at EVAP VSV. EVAP VSV is front VSV on emission control valve set on top of engine, near intake manifold and contains Blue 2-pin electrical connector. see scheme 161, see scheme 163 and see scheme 167. Using jumper wires, connect battery voltage and ground to electrical terminals on EVAP VSV to operate EVAP VSV. Start engine. Go to next step.
  6. Check vacuum reading on vacuum gauge with engine idling. Vacuum reading should be.368-19.713 in. Hg (5.00-268.00 in. H2O) for over 5 seconds. If vacuum reading is within specification, go to next step. If vacuum reading is not within specification, check for loose or restricted vacuum hose to EVAP service port, or for malfunctioning EVAP VSV. To check EVAP VSV operation, see «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000).
  7. Shut engine off. If using hand-held tester to operate EVAP VSV, stop operation of EVAP VSV. Remove hand-held tester. Go to next step. If connecting battery voltage to EVAP VSV to operate EVAP VSV, disconnect jumper wires and reconnect electrical connector on EVAP VSV. Go to next step.
  8. Disconnect vacuum gauge from EVAP service port. Connect pressure gauge to EVAP service port. Install hose crimper on air drain hose near charcoal canister. Perform STEP 1 in illustration. (Scheme 92)and (Scheme 93). Charcoal canister is located near fuel tank. see scheme 161, see scheme 163 and see scheme 167.
  9. Apply 13.5-15.5 in. H2O of pressure to EVAP service port. After 2 minutes of applying the pressure, the pressure should be 7.7-8.8 in. H2O. If pressure is within specification, go to next step. If pressure cannot be maintained, remove hose crimper and check for disconnected vacuum hose between EVAP VSV, charcoal canister and fuel tank. If vacuum hose is properly installed on EVAP VSV, charcoal canister and fuel tank, check for stuck open EVAP VSV. To check EVAP VSV operation, see «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000).
  10. With pressure still applied at EVAP service port, remove fuel tank cap and note pressure reading. Pressure should decrease when fuel tank cap is removed. If pressure decreases when fuel tank cap is removed, remove pressure gauge and hose crimper. Go to next step. If pressure does not decrease when fuel tank cap is removed, remove pressure gauge and hose crimper. Check for restricted vacuum hose between EVAP service port, charcoal canister and fuel tank. Repair or replace vacuum hose as necessary.
  11. To check airtightness of fuel tank and fuel inlet pipe, disconnect EVAP line hose from charcoal canister. Perform STEP 2 in illustration. (Scheme 92)and (Scheme 93). Apply.58 psi (.040 kg/cm 2 ) air pressure to EVAP line hose so pressure inside the fuel tank is.58 psi (.040 kg/cm 2 ). Check that pressure inside fuel tank holds steady for one minute.
  12. If pressure inside fuel tank holds steady for one minute, reinstall EVAP line hose on charcoal canister. Go to next step. If pressure inside fuel will not hold steady for one minute, check for leaking hoses or pipes at fuel tank and fuel inlet pipe, or for leaks at fuel tank or installed components on fuel tank. If no leaks exist, replace fuel tank and fuel inlet pipe. Reinstall EVAP line hose on charcoal canister. Go to next step.
  13. To check overfill check valve and cut-off valve, disconnect purge line hose and EVAP line hose from charcoal canister, and install cap on air drain hose. Perform STEP 3 in illustration. (Scheme 92)and (Scheme 93).
  14. Apply.58 psi (.040 kg/cm 2 ) air pressure to purge line hose fitting on charcoal canister. Perform STEP 3 in illustration. (Scheme 92)and (Scheme 93). Ensure air flows from EVAP line hose when air pressure is applied to purge line hose fitting on charcoal canister. If fuel tank is full of fuel, air may not flow from EVAP line hose, as overfill check valve may be closed. Ensure fuel tank is not full of fuel when checking for airflow at EVAP line hose.
  15. If air flows from EVAP line hose, go to next step. If air does not flow from EVAP line hose, check for restrictions in EVAP line hose and vent line hose. If any hose is restricted, replace hose and recheck operation. If hoses are not restricted, replace overfill check valve and cut-off valve located on top of fuel tank. see scheme 161, see scheme 163 and see scheme 167.
  16. Reinstall purge line hose and EVAP line hose on charcoal canister. To check air inlet line, disconnect air inlet line hose from charcoal canister. Perform STEP 4 in illustration. (Scheme 92)and (Scheme 93). Apply air pressure to air inlet line hose. Air should flow through air inlet line hose. If air flows through air inlet line hose, go to next step. If air does not flow through air inlet line hose, check for restricted air inlet line hose or air inlet line.
  17. To check charcoal canister, disconnect necessary electrical connectors and components for removal of charcoal canister. Disconnect hose at vapor pressure sensor. Disconnect purge line hose, EVAP line hose and air inlet line hose from charcoal canister.
  18. Push connector on vent line hose toward charcoal canister and pinch both sides of retainer on connector, and then disconnect vent line hose with connector from charcoal canister. (Scheme 94)
  19. Remove charcoal canister and vapor pressure sensor retaining bolts. Remove charcoal canister. Inspect charcoal canister for cracks or damage. If charcoal canister is okay, go to next step. If charcoal canister is defective, replace charcoal canister.
  20. To check charcoal canister, install cap on vent port on charcoal canister. (Scheme 95) Apply.26 psi (.018 kg/cm 2 ) air pressure to EVAP port while holding purge port closed. (Scheme 95) Ensure air flows freely from air drain port.
  21. Apply.26 psi (.018 kg/cm 2 ) air pressure to EVAP port while holding air drain port and purge port closed. (Scheme 95) Ensure air does not flow from air inlet port.
  22. Using vacuum pump, apply 1.01 in. Hg of vacuum to purge port. (Scheme 95) Ensure vacuum does not decrease when air inlet port is closed and that vacuum decreases when air inlet port is opened.
  23. While holding air inlet port closed, using vacuum pump, apply 1.01 in. Hg of vacuum to EVAP port. (Scheme 95) Ensure air flows into purge port. Remove cap from vent port. Replace charcoal canister if defective.
  24. Reinstall charcoal canister. If fuel EVAP system operates properly, it may be necessary to check operation of EVAP VSV, canister closed valve Vacuum Switching Valve (VSV), pressure switching valve Vacuum Switching Valve (VSV) and vapor pressure sensor. See «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000), «CANISTER CLOSED VALVE VACUUM SWITCHING VALVE»(ref-133222-S12860731572002021900000), «PRESSURE SWITCHING VALVE VACUUM SWITCHING VALVE»(ref-133222-S26050178852002021900000) and appropriate «VAPOR PRESSURE SENSOR»(ref-133222-S09408301322002021900000) procedure.

Fuel EVAP System Test (Camry & Highlander)

Note. Manufacturer provides testing information for testing airtightness of fuel tank and components along with testing of charcoal canister and fuel EVAP system.

Scheme 85

Scheme 85: Fuel EVAP System Test (Camry & Highlander)
Scheme 85: Fuel EVAP System Test (Camry & Highlander)
  1. Inspect all fuel EVAP system lines and connections for sharp bends or damage. Fuel inlet pipe may also be referred to as fuel filler pipe. Inspect fuel inlet pipe for cracks, damage or fuel leakage. Inspect fuel tank cap for cracks or deformed gasket. Replace components if defective or damaged.
  2. Start engine. Warm engine to normal operating temperature. Shut engine off. Connect vacuum gauge from EVAP System Test Kit (00002-6872A) to EVAP service port. EVAP service port is located in engine compartment, in purge vacuum hose for EVAP system, near air cleaner assembly. see scheme 162and see scheme 164.
  3. Operate EVAP Vacuum Switching Valve (VSV). If Toyota hand-held tester is available to operate EVAP VSV, go to next step. If Toyota hand-held tester is not available to operate EVAP VSV, go to step 5.
  4. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. see scheme 24and see scheme 26. Start engine. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, activate EVAP VSV. Go to step 6.
  5. Disconnect electrical connector at EVAP VSV. EVAP VSV is front VSV on emission control valve set on top of engine, near intake manifold and contains 2-pin electrical connector. see scheme 162and see scheme 164. Using jumper wires, connect battery voltage and ground to electrical terminals on EVAP VSV to operate EVAP VSV. Start engine. Go to next step.
  6. Check vacuum reading on vacuum gauge with engine idling. Vacuum reading should be.368-19.713 in. Hg (5.00-268.00 in. H2O) for over 5 seconds. If vacuum reading is within specification, go to next step. If vacuum reading is not within specification, check for loose or restricted vacuum hose to EVAP service port, or for malfunctioning EVAP VSV. To check EVAP VSV operation, see «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000).
  7. Shut engine off. If using hand-held tester to operate EVAP VSV, stop operation of EVAP VSV. Remove hand-held tester. Go to next step. If connecting battery voltage to EVAP VSV to operate EVAP VSV, disconnect jumper wires and reconnect electrical connector on EVAP VSV. Go to next step.
  8. Disconnect vacuum gauge from EVAP service port. Connect pressure gauge to EVAP service port. Install hose crimper on air drain hose near charcoal canister. Perform STEP 1 in illustration. (Scheme 92)and (Scheme 96). Charcoal canister is located behind the fuel tank.
  9. Apply 13.5-15.5 in. H2O of pressure to EVAP service port. After 2 minutes of applying pressure, pressure should be 7.7-8.8 in. H2O. If pressure is within specification, go to next step. If pressure cannot be maintained, remove hose crimper. Check for disconnected vacuum hose between EVAP VSV, charcoal canister and fuel tank. If vacuum hose is properly installed on EVAP VSV, charcoal canister and fuel tank, check for stuck open EVAP VSV. To check EVAP VSV operation, see «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000).
  10. With pressure still applied at EVAP service port, remove fuel tank cap and note pressure reading. Pressure should decrease when fuel tank cap is removed. If pressure decreases when fuel tank cap is removed, remove pressure gauge and hose crimper. Go to next step. If pressure does not decrease when fuel tank cap is removed, remove pressure gauge and hose crimper. Check for restricted vacuum hose between EVAP service port, charcoal canister and fuel tank. Repair or replace vacuum hose as necessary.
  11. To check airtightness of fuel tank and fuel inlet pipe, disconnect EVAP line hose from charcoal canister. Perform STEP 2 in illustration. (Scheme 92)and (Scheme 96). Apply.58 psi (.040 kg/cm 2 ) air pressure to EVAP line hose so pressure inside fuel tank is.58 psi (.040 kg/cm 2 ). Check that pressure inside fuel tank holds steady for one minute.
  12. If pressure inside fuel tank holds steady for one minute, reinstall EVAP line hose on charcoal canister. Go to next step. If pressure inside fuel will not hold steady for one minute, check for leaking hoses or pipes at fuel tank and fuel inlet pipe, or for leaks at fuel tank or installed components on fuel tank. If no leaks exist, replace fuel tank and fuel inlet pipe. Reinstall EVAP line hose on charcoal canister. Go to next step.
  13. To check overfill check valve and cut-off valve, disconnect purge line hose and EVAP line hose from charcoal canister, and install cap on air drain hose. Perform STEP 3 in illustration. (Scheme 92)and (Scheme 96).
  14. Apply.58 psi (.040 kg/cm 2 ) air pressure to purge line hose fitting on charcoal canister. Perform STEP 3 in illustration. (Scheme 92)and (Scheme 96). Ensure air flows from EVAP line hose when air pressure is applied to purge line hose fitting on charcoal canister. If fuel tank is full of fuel, air may not flow from EVAP line hose, as overfill check valve may be closed. Ensure fuel tank is not full of fuel when checking for airflow at EVAP line hose.
  15. If air flows from EVAP line hose, go to next step. If air does not flow from EVAP line hose, check for restrictions in EVAP line hose and vent line hose. If any hose is restricted, replace hose and recheck operation. If hoses are not restricted, replace overfill check valve and cut-off valve located on top of fuel tank.
  16. Reinstall purge line hose and EVAP line hose on charcoal canister. To check air inlet line, disconnect air inlet line hose from charcoal canister. Perform STEP 4 in illustration. (Scheme 92)and (Scheme 96). Apply air pressure to air inlet line hose. Air should flow through air inlet line hose. If air flows through air inlet line hose, go to next step. If air does not flow through air inlet line hose, check for restricted air inlet line hose or air inlet line.
  17. To check charcoal canister, disconnect necessary electrical connectors and components for removal of charcoal canister. Remove charcoal canister. Inspect charcoal canister for cracks or damage. If charcoal canister is okay, go to next step. If charcoal canister is defective, replace charcoal canister.
  18. Install cap on vent port on charcoal canister. (Scheme 95) Apply.26 psi (.018 kg/cm 2 ) air pressure to EVAP port while holding purge port closed. (Scheme 95) Ensure air flows freely from air drain port.
  19. Apply.26 psi (.018 kg/cm 2 ) air pressure to EVAP port while holding air drain port and purge port closed. (Scheme 95) Ensure air does not flow from air inlet port.
  20. Using vacuum pump, apply 1.01 in. Hg of vacuum to purge port. (Scheme 95) Ensure vacuum does not decrease when air inlet port is closed, and that vacuum decreases when air inlet port is opened.
  21. While holding air inlet port closed, use vacuum pump to apply 1.01 in. Hg of vacuum to EVAP port. (Scheme 95) Ensure air flows into purge port. Remove cap from vent port. Replace charcoal canister if defective.
  22. Reinstall charcoal canister. If fuel EVAP system operates properly, it may be necessary to check operation of EVAP VSV, canister closed valve Vacuum Switching Valve (VSV) and pressure switching valve Vacuum Switching Valve (VSV). See «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000), «CANISTER CLOSED VALVE VACUUM SWITCHING VALVE»(ref-133222-S12860731572002021900000) and «PRESSURE SWITCHING VALVE VACUUM SWITCHING VALVE»(ref-133222-S26050178852002021900000). Manufacturer does provide individual component testing for vapor pressure sensor. If problem exists with vapor pressure sensor, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

Fuel EVAP System Test (Land Cruiser)

Note. Manufacturer provides testing information for testing airtightness of fuel tank and components along with testing of charcoal canister and fuel EVAP system.

Scheme 86

Scheme 86: Fuel EVAP System Test (Land Cruiser)
Scheme 86: Fuel EVAP System Test (Land Cruiser)

Scheme 87

Scheme 87
Scheme 87
  1. Inspect all fuel EVAP system lines and connections for sharp bends or damage. Inspect fuel tank for damage, cracks or fuel leakage. Inspect fuel tank cap for cracks or deformed gasket. Replace components if defective or damaged.
  2. Start engine. Warm engine to normal operating temperature. Shut engine off. Connect vacuum gauge from EVAP System Test Kit (00002-6872A) to EVAP service port. EVAP service port is located in purge vacuum hose for EVAP system near charcoal canister in engine compartment. see scheme 165
  3. Operate EVAP Vacuum Switching Valve (VSV). If Toyota hand-held tester is available to operate EVAP VSV, go to next step. If Toyota hand-held tester is not available to operate EVAP VSV, go to step 5.
  4. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. see scheme 27 Start engine. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, activate EVAP VSV. Go to step 6.
  5. Disconnect electrical connector at EVAP VSV. EVAP VSV is located at driver's side center of intake manifold below intake manifold cover and contains Black 2-Pin electrical connector with Blue/Black and Black/Yellow wires. see scheme 165 Using jumper wires, connect battery voltage and ground to electrical terminals on EVAP VSV to operate EVAP VSV. Start engine. Go to next step.
  6. Check vacuum reading on vacuum gauge with engine idling. Vacuum reading should be.368-19.713 in. Hg (5.00-268.00 in. H2O) for over 5 seconds. If vacuum reading is within specification, go to next step. If vacuum reading is not within specification, check for loose or restricted vacuum hose to EVAP service port, or for malfunctioning EVAP VSV. To check EVAP VSV operation, see «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000).
  7. Shut engine off. If using hand-held tester to operate EVAP VSV, stop operation of EVAP VSV. Remove hand-held tester. Go to next step. If connecting battery voltage to EVAP VSV to operate EVAP VSV, disconnect jumper wires and reconnect electrical connector on EVAP VSV. Go to next step.
  8. Disconnect vacuum gauge from EVAP service port. Connect pressure gauge to EVAP service port. Install hose crimper on air drain hose near charcoal canister. (Scheme 97) Charcoal canister is located at driver's side of engine compartment. see scheme 165
  9. Apply 13.5-15.5 in. H2O of pressure to EVAP service port. After 2 minutes of applying the pressure, the pressure should be 7.7-8.8 in. H2O. If pressure is within specification, go to next step. If pressure cannot be maintained, remove hose crimper and check for disconnected vacuum hose between EVAP VSV, charcoal canister and fuel tank. If vacuum hose is properly installed on EVAP VSV, charcoal canister and fuel tank, check for stuck open EVAP VSV. To check EVAP VSV operation, see «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000).
  10. With pressure still applied at EVAP service port, remove fuel tank cap and note pressure reading. Pressure should decrease when fuel tank cap is removed. If pressure decreases when fuel tank cap is removed, remove pressure gauge and hose crimper. Go to next step. If pressure does not decrease when fuel tank cap is removed, remove pressure gauge and hose crimper. Check for restricted vacuum hose between EVAP service port, charcoal canister and fuel tank. Repair or replace vacuum hose as necessary.
  11. To check charcoal canister, remove charcoal canister. Inspect charcoal canister for cracks or damage. If charcoal canister is okay, go to next step. If charcoal canister is defective, replace charcoal canister.
  12. Apply.26 psi (.018 kg/cm 2 ) air pressure to port "A" while holding port "B" closed. (Scheme 98) Ensure air flows freely from port "D".
  13. Apply.26 psi (.018 kg/cm 2 ) air pressure to port "A" while holding ports "B" and "D" closed. (Scheme 98) Ensure air does not flow port "C".
  14. Using vacuum pump, apply 1.01 in. Hg of vacuum to port "B". Ensure vacuum does not decrease when port "C" is closed and that vacuum decreases when port "C" is opened.
  15. While holding port "C" closed, using vacuum pump, apply.39 in. Hg of vacuum to port "A". Ensure air flows into port "B". Replace charcoal canister if defective.
  16. Reinstall charcoal canister. If fuel EVAP system operates properly, it may be necessary to check operation of EVAP VSV, vapor pressure sensor and vapor pressure sensor Vacuum Switching Valve (VSV). See «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000), «VAPOR PRESSURE SENSOR»(ref-133222-S09408301322002021900000) and «VAPOR PRESSURE SENSOR VACUUM SWITCHING VALVE»(ref-133222-S25455903982002021900000).

Fuel EVAP System Test (Sequoia)

Note. Manufacturer provides testing information for testing airtightness of fuel tank and components along with testing of charcoal canister and fuel EVAP system.

Scheme 88

Scheme 88: Fuel EVAP System Test (Sequoia)
Scheme 88: Fuel EVAP System Test (Sequoia)

Scheme 89

Scheme 89
Scheme 89
  1. Inspect all fuel EVAP system lines and connections for sharp bends or damage. Fuel inlet pipe may also be referred to as fuel filler pipe. Inspect fuel inlet pipe and fuel tank for cracks, damage or fuel leakage. Inspect fuel tank cap for cracks or deformed gasket. Replace components if defective or damaged.
  2. Start engine. Warm engine to normal operating temperature. Shut engine off. Connect vacuum gauge from EVAP System Test Kit (00002-6872A) to EVAP service port. EVAP service port is located in engine compartment, in the purge vacuum hose for EVAP system. see scheme 166
  3. Operate EVAP Vacuum Switching Valve (VSV). If Toyota hand-held tester is available to operate EVAP VSV, go to next step. If Toyota hand-held tester is not available to operate EVAP VSV, go to step 5.
  4. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. see scheme 28 Start engine. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, activate EVAP VSV. Go to step 6.
  5. Disconnect electrical connector at EVAP VSV. EVAP VSV is located at driver's side center of intake manifold and contains Black 2-Pin electrical connector with White/Green and Green/Red wires. see scheme 166 Using jumper wires, connect battery voltage and ground to electrical terminals on EVAP VSV to operate EVAP VSV. Start engine. Go to next step.
  6. Check vacuum reading on vacuum gauge with engine idling. Vacuum reading should be.368-19.713 in. Hg (5.00-268.00 in. H2O) for over 5 seconds. If vacuum reading is within specification, go to next step. If vacuum reading is not within specification, check for loose or restricted vacuum hose to EVAP service port, or for malfunctioning EVAP VSV. To check EVAP VSV operation, see «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000).
  7. Shut engine off. If using hand-held tester to operate EVAP VSV, stop operation of EVAP VSV. Remove hand-held tester. Go to next step. If connecting battery voltage to EVAP VSV to operate EVAP VSV, disconnect jumper wires and reconnect electrical connector on EVAP VSV. Go to next step.
  8. Disconnect vacuum gauge from EVAP service port. Connect pressure gauge to EVAP service port. Install hose crimper on Yellow marked area on air drain hose near charcoal canister. Perform STEP 1 in illustration. (Scheme 99) Charcoal canister is located near fuel tank. see scheme 166
  9. Apply 13.5-15.5 in. H2O of pressure to EVAP service port. After 2 minutes of applying the pressure, the pressure should be 7.7-8.8 in. H2O. If pressure is within specification, go to next step. If pressure cannot be maintained, remove hose crimper and check for disconnected vacuum hose between EVAP VSV, charcoal canister and fuel tank. If vacuum hose is properly installed on EVAP VSV, charcoal canister and fuel tank, check for stuck open EVAP VSV. To check EVAP VSV operation, see «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000).
  10. With pressure still applied at EVAP service port, remove fuel tank cap and note pressure reading. Pressure should decrease when fuel tank cap is removed. If pressure decreases when fuel tank cap is removed, remove pressure gauge and hose crimper. Go to next step. If pressure does not decrease when fuel tank cap is removed, remove pressure gauge and hose crimper. Check for restricted vacuum hose between EVAP service port, charcoal canister and fuel tank. Repair or replace vacuum hose as necessary.
  11. To check airtightness of fuel tank and fuel inlet pipe, disconnect EVAP line hose from charcoal canister. Perform STEP 2 in illustration. (Scheme 99) Apply.58 psi (.040 kg/cm 2 ) air pressure to EVAP line hose so pressure inside the fuel tank is.58 psi (.040 kg/cm 2 ). Check that pressure inside fuel tank holds steady for one minute.
  12. If pressure inside fuel tank holds steady for one minute, reinstall EVAP line hose on charcoal canister. Go to next step. If pressure inside fuel will not hold steady for one minute, check for leaking hoses or pipes at fuel tank and fuel inlet pipe, or for leaks at fuel tank or installed components on fuel tank. If no leaks exist, replace fuel tank and fuel inlet pipe. Reinstall EVAP line hose on charcoal canister. Go to next step.
  13. To check overfill check valve and cut-off valve, disconnect purge line hose and EVAP line hose from charcoal canister, and install cap on end of air drain hose. Perform STEP 3 in illustration. (Scheme 99)
  14. Apply.58 psi (.040 kg/cm 2 ) air pressure to purge line hose fitting on charcoal canister. Perform STEP 3 in illustration. (Scheme 99) Ensure air flows from EVAP line hose when air pressure is applied to purge line hose fitting on charcoal canister. If fuel tank is full of fuel, air may not flow from EVAP line hose, as overfill check valve may be closed. Ensure fuel tank is not full of fuel when checking for airflow at EVAP line hose.
  15. If air flows from EVAP line hose, go to next step. If air does not flow from EVAP line hose, check for restrictions in EVAP line hose and vent line hose. If any hose is restricted, replace hose and recheck operation. If hoses are not restricted, replace overfill check valve and cut-off valve located on top of fuel tank.
  16. Reinstall purge line hose and EVAP line hose on charcoal canister. To check air inlet line, disconnect air inlet line hose from charcoal canister. Perform STEP 4 in illustration. (Scheme 99) Apply air pressure to air inlet line hose. Air should flow through air inlet line hose. If air flows through air inlet line hose, go to next step. If air does not flow through air inlet line hose, check for restricted air inlet line hose or air inlet line.
  17. To check charcoal canister, remove charcoal canister. Inspect charcoal canister for cracks or damage. If charcoal canister is okay, go to next step. If charcoal canister is defective, replace charcoal canister.
  18. Install cap on vent port on charcoal canister. see scheme 187 Apply.26 psi (.018 kg/cm 2 ) air pressure to EVAP port while holding purge port closed. see scheme 187 Ensure air flows freely from air drain port.
  19. Apply.26 psi (.018 kg/cm 2 ) air pressure to EVAP port while holding air drain port and purge port closed. see scheme 187 Ensure air does not flow from air inlet port.
  20. Using vacuum pump, apply 1.01 in. Hg of vacuum to purge port. see scheme 187 Ensure vacuum does not decrease when air inlet port is closed and that vacuum decreases when air inlet port is opened.
  21. While holding air inlet port closed, using vacuum pump, apply 1.01 in. Hg of vacuum to EVAP port. see scheme 187 Ensure air flows into purge port. Remove cap from vent port. Replace charcoal canister if defective.
  22. Reinstall charcoal canister. If fuel EVAP system operates properly, it may be necessary to check operation of EVAP VSV, canister closed valve Vacuum Switching Valve (VSV), pressure switching valve Vacuum Switching Valve (VSV) and vapor pressure sensor. See «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000), «CANISTER CLOSED VALVE VACUUM SWITCHING VALVE»(ref-133222-S12860731572002021900000), «PRESSURE SWITCHING VALVE VACUUM SWITCHING VALVE»(ref-133222-S26050178852002021900000) and «VAPOR PRESSURE SENSOR»(ref-133222-S39373852262002021900000).

Fuel EVAP System Test (Tacoma & 4Runner)

Note. Manufacturer provides testing information for testing airtightness of fuel tank and components along with testing of charcoal canister and fuel EVAP system.

Scheme 90

Scheme 90: Fuel EVAP System Test (Tacoma & 4Runner)
Scheme 90: Fuel EVAP System Test (Tacoma & 4Runner)

Scheme 91

Scheme 91
Scheme 91

Scheme 92

Scheme 92
Scheme 92

Scheme 93

Scheme 93
Scheme 93
  1. Inspect all fuel EVAP system lines and connections for sharp bends or damage. Fuel inlet pipe may also be referred to as fuel filler pipe. Inspect fuel inlet pipe for cracks, damage or fuel leakage. Inspect fuel tank cap for cracks or deformed gasket. Replace components if defective or damaged.
  2. Start engine. Warm engine to normal operating temperature. Shut engine off. Connect vacuum gauge from EVAP System Test Kit (00002-6872A) to EVAP service port. EVAP service port is located in engine compartment, in the purge vacuum hose for EVAP system. (Scheme 81)and (Scheme 84).
  3. Operate EVAP Vacuum Switching Valve (VSV). If Toyota hand-held tester is available to operate EVAP VSV, go to next step. If Toyota hand-held tester is not available to operate EVAP VSV, go to step 5.
  4. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. see scheme 30and see scheme 32. Start engine. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, activate EVAP VSV. Go to step 6.
  5. Disconnect electrical connector at EVAP VSV. EVAP VSV is located in engine compartment, on bracket bolted to inside of driver's side front fender panel and contains Black 2-pin electrical connector. (Scheme 81)and (Scheme 84). Using jumper wires, connect battery voltage and ground to electrical terminals on EVAP VSV to operate EVAP VSV. Start engine. Go to next step.
  6. Check vacuum reading on vacuum gauge with engine idling. Vacuum reading should be.368-19.713 in. Hg (5.00-268.00 in. H2O) for over 5 seconds. If vacuum reading is within specification, go to next step. If vacuum reading is not within specification, check for loose or restricted vacuum hose to EVAP service port, or for malfunctioning EVAP VSV. To check EVAP VSV operation, see «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000).
  7. Shut engine off. If using hand-held tester to operate EVAP VSV, stop operation of EVAP VSV. Remove hand-held tester. Go to next step. If connecting battery voltage to EVAP VSV to operate EVAP VSV, disconnect jumper wires and reconnect electrical connector on EVAP VSV. Go to next step.
  8. Disconnect vacuum gauge from EVAP service port. Connect pressure gauge to EVAP service port. Install hose crimper on air drain hose near charcoal canister. Perform STEP 1 in illustration. see scheme 188and see scheme 189. Charcoal canister is located near fuel tank. (Scheme 81)and (Scheme 84).
  9. Apply 13.5-15.5 in. H2O of pressure to EVAP service port. After 2 minutes of applying the pressure, the pressure should be 7.7-8.8 in. H2O. If pressure is within specification, go to next step. If pressure cannot be maintained, remove hose crimper and check for disconnected vacuum hose between EVAP VSV, charcoal canister and fuel tank. If vacuum hose is properly installed on EVAP VSV, charcoal canister and fuel tank, check for stuck open EVAP VSV. To check EVAP VSV operation, see «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000).
  10. With pressure still applied at EVAP service port, remove fuel tank cap and note pressure reading. Pressure should decrease when fuel tank cap is removed. If pressure decreases when fuel tank cap is removed, remove pressure gauge and hose crimper. Go to next step. If pressure does not decrease when fuel tank cap is removed, remove pressure gauge and hose crimper. Check for restricted vacuum hose between EVAP service port, charcoal canister and fuel tank. Repair or replace vacuum hose as necessary.
  11. To check airtightness of fuel tank and fuel inlet pipe, disconnect EVAP line hose from charcoal canister. Perform STEP 2 in illustration. see scheme 188and see scheme 189. Apply.58 psi (.040 kg/cm 2 ) air pressure to EVAP line hose so pressure inside the fuel tank is.58 psi (.040 kg/cm 2 ). Check that pressure inside fuel tank holds steady for one minute.
  12. If pressure inside fuel tank holds steady for one minute, reinstall EVAP line hose on charcoal canister. Go to next step. If pressure inside fuel will not hold steady for one minute, check for leaking hoses or pipes at fuel tank and fuel inlet pipe, or for leaks at fuel tank or installed components on fuel tank. If no leaks exist, replace fuel tank and fuel inlet pipe. Reinstall EVAP line hose on charcoal canister. Go to next step.
  13. To check overfill check valve and cut-off valve, disconnect purge line hose and EVAP line hose from charcoal canister, and install cap on air drain hose. Perform STEP 3 in illustration. see scheme 188and see scheme 189.
  14. Apply.58 psi (.040 kg/cm 2 ) air pressure to purge line hose fitting on charcoal canister. Perform STEP 3 in illustration. see scheme 188and see scheme 189. Ensure air flows from EVAP line hose when air pressure is applied to purge line hose fitting on charcoal canister. If fuel tank is full of fuel, air may not flow from EVAP line hose, as overfill check valve may be closed. Ensure fuel tank is not full of fuel when checking for airflow at EVAP line hose.
  15. If air flows from EVAP line hose, go to next step. If air does not flow from EVAP line hose, check for restrictions in EVAP line hose and vent line hose. If any hose is restricted, replace hose and recheck operation. If hoses are not restricted, replace overfill check valve and cut-off valve located on top of fuel tank. (Scheme 81)and (Scheme 84).
  16. Reinstall purge line hose and EVAP line hose on charcoal canister. To check air inlet line, disconnect air inlet line hose from charcoal canister. Perform STEP 4 in illustration. see scheme 188and see scheme 189. Apply air pressure to air inlet line hose. Air should flow through air inlet line hose. If air flows through air inlet line hose, go to next step. If air does not flow through air inlet line hose, check for restricted air inlet line hose or air inlet line.
  17. To check charcoal canister, remove spare tire for access to charcoal canister. Disconnect necessary electrical connectors for removal of charcoal canister. Disconnect purge line hose, EVAP line hose and air inlet line hose from charcoal canister.
  18. Push connector on vent line hose toward charcoal canister and pinch both sides of retainer on connector, and then disconnect vent line hose with connector from charcoal canister. see scheme 190
  19. Remove charcoal canister retaining bolts. Remove charcoal canister. Inspect charcoal canister for cracks or damage. If charcoal canister is okay, go to next step. If charcoal canister is defective, replace charcoal canister.
  20. Install hose and cap on vent port on charcoal canister. see scheme 191 Apply.26 psi (.018 kg/cm 2 ) air pressure to EVAP port while holding purge port closed. see scheme 191 Ensure air flows freely from air drain port.
  21. Apply.26 psi (.018 kg/cm 2 ) air pressure to EVAP port while holding air drain port and purge port closed. see scheme 191 Ensure air does not flow from air inlet port.
  22. Using vacuum pump, apply 1.01 in. Hg of vacuum to purge port. see scheme 191 Ensure vacuum does not decrease when air inlet port is closed and that vacuum decreases when air inlet port is opened.
  23. While holding air inlet port closed, using vacuum pump, apply 1.01 in. Hg of vacuum to EVAP port. see scheme 191 Ensure air flows into purge port. Remove hose and cap from vent port. Replace charcoal canister if defective.
  24. Reinstall charcoal canister. If fuel EVAP system operates properly, it may be necessary to check operation of EVAP VSV, canister closed valve Vacuum Switching Valve (VSV), pressure switching valve Vacuum Switching Valve (VSV) and vapor pressure sensor. See «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000), «CANISTER CLOSED VALVE VACUUM SWITCHING VALVE»(ref-133222-S12860731572002021900000), «PRESSURE SWITCHING VALVE VACUUM SWITCHING VALVE»(ref-133222-S26050178852002021900000) and «VAPOR PRESSURE SENSOR»(ref-133222-S29630090972002022500000).

Fuel EVAP System Test (Tundra)

Note. Manufacturer provides testing information for testing airtightness of fuel tank and components along with testing of charcoal canister and fuel EVAP system.

Scheme 94

Scheme 94: Fuel EVAP System Test (Tundra)
Scheme 94: Fuel EVAP System Test (Tundra)

Scheme 95

Scheme 95
Scheme 95
  1. Inspect all fuel EVAP system lines and connections for sharp bends or damage. Inspect fuel tank for damage, cracks or fuel leakage. Inspect fuel tank cap for cracks or deformed gasket. Replace components if defective or damaged.
  2. Start engine. Warm engine to normal operating temperature. Shut engine off. Connect vacuum gauge from EVAP System Test Kit (00002-6872A) to EVAP service port. EVAP service port is located in purge vacuum hose for EVAP system near charcoal canister in engine compartment. (Scheme 82)and (Scheme 83).
  3. Operate EVAP Vacuum Switching Valve (VSV). If Toyota hand-held tester is available to operate EVAP VSV, go to next step. If Toyota hand-held tester is not available to operate EVAP VSV, go to step 5.
  4. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. see scheme 31 Start engine. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, activate EVAP VSV. Go to step 6.
  5. Disconnect electrical connector at EVAP VSV. On 3.4L V6, EVAP VSV is located at driver's side rear corner of air intake chamber and contains Black 2-pin connector. (Scheme 82) On 4.7L V8, EVAP VSV is located at driver's side center of intake manifold and contains Black 2-pin electrical connector. (Scheme 83) On all models, using jumper wires, connect battery voltage and ground to electrical terminals on EVAP VSV to operate EVAP VSV. Start engine. Go to next step.
  6. Check vacuum reading on vacuum gauge with engine idling. Vacuum reading should be.368-19.713 in. Hg (5.00-268.00 in. H2O) for over 5 seconds. If vacuum reading is within specification, go to next step. If vacuum reading is not within specification, check for loose or restricted vacuum hose to EVAP service port, or for malfunctioning EVAP VSV. To check EVAP VSV operation, see «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000).
  7. Shut engine off. If using hand-held tester to operate EVAP VSV, stop operation of EVAP VSV. Remove hand-held tester. Go to next step. If connecting battery voltage to EVAP VSV to operate EVAP VSV, disconnect jumper wires and reconnect electrical connector on EVAP VSV. Go to next step.
  8. Disconnect vacuum gauge from EVAP service port. Connect pressure gauge to EVAP service port. Install hose crimper on Yellow marked area on air drain hose near charcoal canister. see scheme 192 Charcoal canister is located in driver's side of engine compartment. (Scheme 82)and (Scheme 83).
  9. Apply 13.5-15.5 in. H2O of pressure to EVAP service port. After 2 minutes of applying the pressure, the pressure should be 7.7-8.8 in. H2O. If pressure is within specification, go to next step. If pressure cannot be maintained, remove hose crimper and check for disconnected vacuum hose between EVAP VSV, charcoal canister and fuel tank. If vacuum hose is properly installed on EVAP VSV, charcoal canister and fuel tank, check for stuck open EVAP VSV. To check EVAP VSV operation, see «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000).
  10. With pressure still applied at EVAP service port, remove fuel tank cap and note pressure reading. Pressure should decrease when fuel tank cap is removed. If pressure decreases when fuel tank cap is removed, remove pressure gauge and hose crimper. Go to next step. If pressure does not decrease when fuel tank cap is removed, remove pressure gauge and hose crimper. Check for restricted vacuum hose between EVAP service port, charcoal canister and fuel tank. Repair or replace vacuum hose as necessary.
  11. To check charcoal canister, remove charcoal canister. Inspect charcoal canister for cracks or damage. If charcoal canister is okay, go to next step. If charcoal canister is defective, replace charcoal canister.
  12. Apply.26 psi (.018 kg/cm 2 ) air pressure to port "A" while holding port "B" closed. see scheme 193 Ensure air flows freely from port "D".
  13. Apply.26 psi (.018 kg/cm 2 ) air pressure to port "A" while holding ports "B" and "D" closed. see scheme 193 Ensure air does not flow from port "C".
  14. Using vacuum pump, apply 1.01 in. Hg of vacuum to port "B". Ensure vacuum does not decrease when port "C" is closed and that vacuum decreases when port "C" is opened.
  15. While holding port "C" closed, using vacuum pump, apply.39 in. Hg of vacuum to port "A". Ensure air flows into port "B". Replace charcoal canister if defective.
  16. Reinstall charcoal canister. If fuel EVAP system operates properly, it may be necessary to check operation of EVAP VSV, vapor pressure sensor and vapor pressure sensor Vacuum Switching Valve (VSV). See «EVAP VACUUM SWITCHING VALVE»(ref-133222-S03907496252002021900000), «VAPOR PRESSURE SENSOR»(ref-133222-S09408301322002021900000) and «VAPOR PRESSURE SENSOR VACUUM SWITCHING VALVE»(ref-133222-S25455903982002021900000).

Scheme 96

Scheme 96: Canister Closed Valve Vacuum Switching Valve (Avalon, Camry, Camry Solara, Highlander, Sequoia, Sien
Scheme 96: Canister Closed Valve Vacuum Switching Valve (Avalon, Camry, Camry Solara, Highlander, Sequoia, Sien

Scheme 97

Scheme 97
Scheme 97

Scheme 98

Scheme 98
Scheme 98

Scheme 99

Scheme 99
Scheme 99
  1. Disconnect electrical connector at Canister Closed Valve Vacuum Switching Valve (CCV VSV). On Avalon, Camry, Camry Solara, Highlander, and Sienna, CCV VSV is located on air cleaner housing. see scheme 161- see scheme 167. On Sequoia, CCV VSV is located on bracket at driver's side of engine compartment, just to the rear of fuse/relay box and contains a 2-pin electrical connector with White/Blue and Black/Red wires. see scheme 166 On Tacoma and 4Runner, CCV VSV is located in engine compartment, on bracket bolted to inside of driver's side front fender panel. (Scheme 81)and (Scheme 84).
  2. On all models, remove CCV VSV. Using ohmmeter, check that continuity exists between electrical terminals on CCV VSV and that resistance is within specification. See «CCV VSV RESISTANCE»(ref-133222-S15041635522002021900000) table. Replace CCV VSV if no continuity exists or resistance is not within specification. CCV VSV RESISTANCE Application Ohms @ 68°F (20°C) Avalon (1) Camry 25-30 Camry Solara (1) Highlander 24-30 Sequoia 25-30 Sienna, Tacoma & 4Runner (1) (1) Resistance should be 25-30 ohms at 68°F (20°C) and 33-42 ohms at 248 °F (120°C).
  3. Ensure no continuity exists between each electrical terminal and body of CCV VSV. Replace CCV VSV if continuity exists between electrical terminal and body of CCV VSV.
  4. To test CCV VSV operation, apply air pressure to port "A". Ensure air flows from port "B". Perform STEP 1 in illustration. see scheme 194- see scheme 197.
  5. Apply battery voltage and ground to electrical terminals on CCV VSV. Apply air pressure to port "A". Ensure air does not flow from port "B". Perform STEP 2 in illustration. see scheme 194- see scheme 197. Replace CCV VSV if defective.

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