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

Testing & Diagnostics 20 illustrations ~7629 words

Fuel EVAP System Test (Avalon, Camry, 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 61

Scheme 61: Fuel EVAP System Test (Avalon, Camry, Camry Solara & Sienna)
Scheme 61: Fuel EVAP System Test (Avalon, Camry, Camry Solara & Sienna)

Scheme 62

Scheme 62
Scheme 62

Scheme 63

Scheme 63
Scheme 63

Scheme 64

Scheme 64
Scheme 64
  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-01) to EVAP service port. EVAP service port is located in engine compartment, in the purge vacuum hose for EVAP system. see scheme 139, see scheme 140 and see scheme 144.
  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. see scheme 14- see scheme 16 and see scheme 20. 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 139, see scheme 140 and see scheme 144. 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-63408-S13313503872001020500000).
  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 66)and (Scheme 67). Charcoal canister is located near fuel tank. see scheme 139, see scheme 140 and see scheme 144.
  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-63408-S13313503872001020500000).
  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 66)and (Scheme 67). 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 66)and (Scheme 67).
  14. Apply.58 psi (.040 kg/cm 2 ) air pressure to purge line hose fitting on charcoal canister. Perform STEP 3 in illustration. (Scheme 66)and (Scheme 67). 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 139, see scheme 140 and see scheme 144.
  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 66)and (Scheme 67). 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 68)
  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 69) Apply.26 psi (.018 kg/cm 2 ) air pressure to EVAP port while holding purge port closed. (Scheme 69) 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 69) Ensure air does not flow from air inlet port.
  22. Using vacuum pump, apply 1.01 in. Hg of vacuum to purge port. (Scheme 69) 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 69) 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-63408-S13313503872001020500000), «CANISTER CLOSED VALVE VACUUM SWITCHING VALVE»(ref-63408-S29457026762001020500000), «PRESSURE SWITCHING VALVE VACUUM SWITCHING VALVE»(ref-63408-S20206948602001020500000) and appropriate «VAPOR PRESSURE SENSOR»(ref-63408-S07672871262001020500000) procedure.

Fuel EVAP System Test (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 65

Scheme 65: Fuel EVAP System Test (Highlander)
Scheme 65: Fuel EVAP System Test (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-01) 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 141
  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. see scheme 17 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 141 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-63408-S13313503872001020500000).
  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 70) Charcoal canister is located at driver's side of vehicle, behind 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-63408-S13313503872001020500000).
  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 70) 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 70)
  14. Apply.58 psi (.040 kg/cm 2 ) air pressure to purge line hose fitting on charcoal canister. Perform STEP 3 in illustration. (Scheme 70) 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 70) 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 69) Apply.26 psi (.018 kg/cm 2 ) air pressure to EVAP port while holding purge port closed. (Scheme 69) 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 69) Ensure air does not flow from air inlet port.
  20. Using vacuum pump, apply 1.01 in. Hg of vacuum to purge port. (Scheme 69) 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 69) 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-63408-S13313503872001020500000), «CANISTER CLOSED VALVE VACUUM SWITCHING VALVE»(ref-63408-S29457026762001020500000) and «PRESSURE SWITCHING VALVE VACUUM SWITCHING VALVE»(ref-63408-S20206948602001020500000). 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 66

Scheme 66: Fuel EVAP System Test (Land Cruiser)
Scheme 66: Fuel EVAP System Test (Land Cruiser)

Scheme 67

Scheme 67
Scheme 67
  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-01) to EVAP service port. EVAP service port is located in purge vacuum hose for EVAP system near charcoal canister in engine compartment. see scheme 142
  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. see scheme 18 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 142 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-63408-S13313503872001020500000).
  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 71) Charcoal canister is located at driver's side of engine compartment. see scheme 142
  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-63408-S13313503872001020500000).
  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 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 72) 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 72) 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-63408-S13313503872001020500000), «VAPOR PRESSURE SENSOR»(ref-63408-S07672871262001020500000) and «VAPOR PRESSURE SENSOR VACUUM SWITCHING VALVE»(ref-63408-S42592789572001020500000).

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 68

Scheme 68: Fuel EVAP System Test (Sequoia)
Scheme 68: Fuel EVAP System Test (Sequoia)

Scheme 69

Scheme 69
Scheme 69
  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-01) to EVAP service port. EVAP service port is located in engine compartment, in the purge vacuum hose for EVAP system. see scheme 143
  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. see scheme 19 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 143 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-63408-S13313503872001020500000).
  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 73) Charcoal canister is located near fuel tank. see scheme 143
  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-63408-S13313503872001020500000).
  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 73) 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 73)
  14. Apply.58 psi (.040 kg/cm 2 ) air pressure to purge line hose fitting on charcoal canister. Perform STEP 3 in illustration. (Scheme 73) 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 73) 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. (Scheme 74) Apply.26 psi (.018 kg/cm 2 ) air pressure to EVAP port while holding purge port closed. (Scheme 74) 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 74) Ensure air does not flow from air inlet port.
  20. Using vacuum pump, apply 1.01 in. Hg of vacuum to purge port. (Scheme 74) 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. (Scheme 74) 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-63408-S13313503872001020500000), «CANISTER CLOSED VALVE VACUUM SWITCHING VALVE»(ref-63408-S29457026762001020500000), «PRESSURE SWITCHING VALVE VACUUM SWITCHING VALVE»(ref-63408-S20206948602001020500000) and «VAPOR PRESSURE SENSOR»(ref-63408-S15480547392001021600000).

Fuel EVAP System Test (Tacoma)

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

Scheme 70

Scheme 70: Fuel EVAP System Test (Tacoma)
Scheme 70: Fuel EVAP System Test (Tacoma)

Scheme 71

Scheme 71
Scheme 71
  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-01) to EVAP service port. EVAP service port is located in purge vacuum hose for EVAP system near charcoal canister in engine compartment. see scheme 145
  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. see scheme 21 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 on end of charcoal canister. see scheme 145 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-63408-S13313503872001020500000).
  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 75) Charcoal canister is located in driver's side of engine compartment. see scheme 145
  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-63408-S13313503872001020500000).
  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. Remove all vacuum switching valves from 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. Install plugs on ports "A" and "B" on charcoal canister. (Scheme 76) Apply.21 psi (.015 kg/cm 2 ) air pressure to port "D" while holding port "C" closed. (Scheme 76) Ensure air flows freely from port "E".
  13. Apply.21 psi (.015 kg/cm 2 ) air pressure to port "D" while holding ports "C" and "E" closed. (Scheme 76) Ensure air does not flow from port "F".
  14. Using vacuum pump, apply.87 in. Hg of vacuum to port "C". Ensure vacuum does not decrease when port "F" is closed and that vacuum decreases when port "F" is opened.
  15. While holding port "F" closed, using vacuum pump, apply.87 in. Hg of vacuum to port "D". Ensure vacuum does not decrease when port "C" is closed and that vacuum decreases when port "C" is opened. Replace charcoal canister if defective.
  16. Remove plugs and 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-63408-S13313503872001020500000), «VAPOR PRESSURE SENSOR»(ref-63408-S07672871262001020500000) and «VAPOR PRESSURE SENSOR VACUUM SWITCHING VALVE»(ref-63408-S42592789572001020500000).

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 72

Scheme 72: Fuel EVAP System Test (Tundra)
Scheme 72: Fuel EVAP System Test (Tundra)

Scheme 73

Scheme 73
Scheme 73
  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-01) to EVAP service port. EVAP service port is located in purge vacuum hose for EVAP system near charcoal canister in engine compartment. see scheme 146and see scheme 147.
  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. see scheme 22 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. see scheme 146 On 4.7L V8, EVAP VSV is located at driver's side center of intake manifold and contains Black 2-pin electrical connector. see scheme 147 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-63408-S13313503872001020500000).
  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. (Scheme 77) Charcoal canister is located in driver's side of engine compartment. see scheme 146and see scheme 147.
  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-63408-S13313503872001020500000).
  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" on while holding port "B" closed. (Scheme 78) 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 78) 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-63408-S13313503872001020500000), «VAPOR PRESSURE SENSOR»(ref-63408-S07672871262001020500000) and «VAPOR PRESSURE SENSOR VACUUM SWITCHING VALVE»(ref-63408-S42592789572001020500000).

Fuel EVAP System Test (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 74

Scheme 74: Fuel EVAP System Test (4Runner)
Scheme 74: Fuel EVAP System Test (4Runner)

Scheme 75

Scheme 75
Scheme 75

Scheme 76

Scheme 76
Scheme 76
  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-01) to EVAP service port. EVAP service port is located in engine compartment, in the purge vacuum hose for EVAP system. see scheme 148
  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. see scheme 23 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. see scheme 148 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-63408-S13313503872001020500000).
  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 79) Charcoal canister is located near fuel tank. see scheme 148
  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-63408-S13313503872001020500000).
  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 79) 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 79)
  14. Apply.58 psi (.040 kg/cm 2 ) air pressure to purge line hose fitting on charcoal canister. Perform STEP 3 in illustration. (Scheme 79) 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 148
  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 79) 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. (Scheme 80)
  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 vent port on charcoal canister. see scheme 169 Apply.26 psi (.018 kg/cm 2 ) air pressure to EVAP port while holding purge port closed. see scheme 169 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 169 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 169 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 169 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-63408-S13313503872001020500000), «CANISTER CLOSED VALVE VACUUM SWITCHING VALVE»(ref-63408-S29457026762001020500000), «PRESSURE SWITCHING VALVE VACUUM SWITCHING VALVE»(ref-63408-S20206948602001020500000) and «VAPOR PRESSURE SENSOR»(ref-63408-S15480547392001021600000).

Scheme 77

Scheme 77: Canister Closed Valve Vacuum Switching Valve (Avalon, Camry, Camry Solara, Highlander, Sequoia, Sien
Scheme 77: Canister Closed Valve Vacuum Switching Valve (Avalon, Camry, Camry Solara, Highlander, Sequoia, Sien

Scheme 78

Scheme 78
Scheme 78

Scheme 79

Scheme 79
Scheme 79

Scheme 80

Scheme 80
Scheme 80
  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 near air cleaner housing. see scheme 139- see scheme 144. 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 143 On 4Runner, CCV VSV is located in engine compartment, on bracket bolted to inside of driver's side front fender panel. see scheme 148
  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-63408-S40056124932001021600000) table. Replace CCV VSV if no continuity exists or resistance is not within specification. CCV VSV RESISTANCE Application Ohms @ 68°F (20°C) Avalon, Camry & Camry Solara (1) Highlander 24-30 Sequoia 25-30 Sienna & 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 170- see scheme 173.
  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 170- see scheme 173. Replace CCV VSV if defective.

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