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Home >> Toyota Truck >> 2010 >> Highlander 2WD V6-3.5L (2GR-FE) >> Repair and Diagnosis >> Powertrain Management >> Computers and Control Systems >> Testing and Inspection >> Component Tests and General Diagnostics >> EVAP System >> Part 2

Part 2





2GR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: EVAP System
- EVAP System


13. CHECK FUEL TANK CAP ASSEMBLY

(a) Check that the fuel tank cap is correctly installed and confirm the fuel tank cap meets OEM specification.

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

(1) Tighten the fuel tank cap.

(2) Remove the fuel tank cap and install it onto the fuel tank cap adaptor.

(3) Connect the EVAP tester pump hose to the adaptor, and pressurize the cap to 3.2 to 3.7 kPa (24 to 28 mmHg) using an EVAP tester pump.

(4) Seal the adaptor and wait for 2 minutes.

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

Result:





C -- REPLACE FUEL TANK CAP ASSEMBLY

B -- CORRECTLY REINSTALL OR REPLACE FUEL TANK CAP

A -- LOCATE EVAP LEAK

14. INSPECT PURGE VSV

(a) Turn the ignition switch off.





(b) Disconnect the purge VSV connector.

(c) Disconnect the hose (connected to the canister) from the purge VSV.

(d) Start the engine.

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

Result:





Text in Illustration





(f) Reconnect the purge VSV connector.

(g) Reconnect the hose.

B -- REPLACE VACUUM SWITCHING VALVE NO. 1 (PURGE VSV)

A -- REPLACE ECM

15. CHECK EVAP HOSE (PURGE VSV - THROTTLE BODY)

(a) Disconnect the hose (connected to the throttle body) from the purge VSV.





(b) Start the engine.

(c) Confirm that the hose has suction with your fingers.

Result:





Text in Illustration





(d) Reconnect the hose.

B -- INSPECT THROTTLE BODY
A -- Continue to next step.

16. INSPECT VACUUM SWITCHING VALVE NO. 1 (PURGE VSV)

(a) Remove the purge VSV.





(b) Apply battery voltage to the terminals of the purge VSV.

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

Result:





Text in Illustration





(d) Install the purge VSV.

B -- REPLACE VACUUM SWITCHING VALVE NO. 1 (PURGE VSV)
A -- Continue to next step.

17. CHECK HARNESS AND CONNECTOR (POWER SOURCE OF PURGE VSV)

(a) Disconnect the purge VSV connector.





(b) Turn the ignition switch on (IG).

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

Standard voltage:





Text in Illustration





Result:





(d) Reconnect the purge VSV connector.

B -- REPAIR OR REPLACE HARNESS OR CONNECTOR
A -- Continue to next step.

18. CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM)

(a) Disconnect the ECM connector and the purge VSV connector.

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

Standard resistance:





(c) Reconnect the purge VSV connector.

(d) Reconnect the ECM connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE ECM

19. PERFORM ACTIVE TEST USING TECHSTREAM (FOR VENT VALVE)

(a) Turn the ignition switch on (IG).





(b) Select the following menu items on the tester: Powertrain / Engine and ECT / Active Test / Activate the VSV for Vent Valve.

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

Standard voltage:





Text in Illustration





Result:





B -- REPLACE ECM

A -- INSPECT PUMP MODULE (VENT VALVE OPERATION)

20. PERFORM ACTIVE TEST USING TECHSTREAM (FOR VENT VALVE)

(a) Turn the ignition switch on (IG).





(b) Select the following menu items on the tester: Powertrain / Engine and ECT / Active Test / Activate the VSV for Vent Valve.

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

Standard voltage:





Text in Illustration





Result:





C -- REPLACE ECM

B -- INSPECT PUMP MODULE (VENT VALVE OPERATION)
A -- Continue to next step.

21. INSPECT PUMP MODULE (POWER SOURCE FOR VENT VALVE)

(a) Turn the ignition switch off.





(b) Disconnect the canister pomp module connector.

(c) Turn the ignition switch on (IG).

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

Standard voltage:





Text in Illustration





Result:





(e) Reconnect the canister pomp module connector.

B -- REPAIR OR REPLACE HARNESS OR CONNECTOR
A -- Continue to next step.

22. INSPECT PUMP MODULE (VENT VALVE OPERATION)

(a) Turn the ignition switch off.





(b) Disconnect the canister pomp module connector.

(c) Apply the battery voltage to terminals 9 and 8 of the pump module.

(d) Touch the pump module to confirm the vent valve operation.

Result:





(e) Reconnect the canister pomp module connector.

B -- REPLACE CHARCOAL CANISTER ASSEMBLY

A -- REPAIR OR REPLACE HARNESS OR CONNECTOR

23. PERFORM ACTIVE TEST USING TECHSTREAM (FOR CANISTER PUMP MODULE (VACUUM PUMP))

(a) Select the following menu items on the tester: Powertrain / Engine and ECT / Active Test / Activate the Vacuum Pump.





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

Standard voltage:





Text in Illustration





Result:





B -- REPLACE ECM
A -- Continue to next step.

24. CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - ECM)

(a) Turn the ignition switch off.





(b) Disconnect the canister pomp module connector.

(c) Turn the ignition switch on (IG).

(d) Select the following menu items on the tester: Powertrain / Engine and ECT / Active Test / Activate the Vacuum Pump.

(e) Turn the vacuum pump ON.

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

Standard voltage:





Text in Illustration





Result:





(g) Reconnect the canister pomp module connector.

B -- REPAIR OR REPLACE HARNESS OR CONNECTOR
A -- Continue to next step.

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

(a) Disconnect the canister pomp module connector.





(b) Turn the ignition switch off.

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

Standard resistance:





Text in Illustration





Result:





(d) Reconnect the canister pomp module connector.

B -- REPAIR OR REPLACE HARNESS OR CONNECTOR

A -- REPLACE CHARCOAL CANISTER ASSEMBLY

26. INSPECT THROTTLE BODY

(a) Stop the engine.

(b) Disconnect the EVAP hose from the throttle body.

(c) Start the engine.

(d) Confirm that the port of the throttle body has suction with your fingers.

Result:





(e) Reconnect the EVAP hose.

B -- INSPECT THROTTLE BODY

A -- REPLACE EVAP HOSE (THROTTLE BODY - PURGE VSV)

27. CORRECTLY REINSTALL OR REPLACE FUEL TANK CAP

HINT
* When reinstalling the fuel tank cap, tighten it until a few click sounds are heard.
* When replacing the fuel tank cap, use a fuel tank cap that meets OEM specifications, and tighten it until a few click sounds are heard.

NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)

28. REPLACE FUEL TANK CAP ASSEMBLY

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

NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)

29. LOCATE EVAP LEAK

(a) Disconnect the vent hose.





Text in Illustration





(b) Connect the EVAP pressure tester tool to the canister with the adapter.





Text in Illustration





(c) Pressurize the EVAP system by 3.2 to 3.7 kPa (24 to 28 mmHg).

(d) Apply soapy water to the piping and the connecting parts of the EVAP system.

(e) Look for areas where bubbles appear. This indicates a leak point.

(f) Repair or replace the leak point.

NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)

30. REPLACE CHARCOAL CANISTER ASSEMBLY

(a) Replace the charcoal canister assembly Components.

NOTICE:
When replacing the canister, check the canister pump module interior and related pipes for water, fuel and other liquids. If liquids are present, check for disconnections and/or cracks in the following: 1) the pipe from the air inlet port to the canister pump module; 2) the canister filter; 3) the fuel tank vent hose.





Text in Illustration





NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)

31. REPLACE VACUUM SWITCHING VALVE NO. 1 (PURGE VSV)

(a) Disconnect the connector and 2 hoses from the purge VSV.





(b) Remove the purge VSV.

Text in Illustration





(c) Install a new purge VSV.

(d) Reconnect the connector and 2 hoses.

NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)

32. REPAIR OR REPLACE HARNESS OR CONNECTOR

NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)

33. REPLACE EVAP HOSE (THROTTLE BODY - PURGE VSV)

NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)

34. INSPECT THROTTLE BODY

(a) Remove the throttle body Removal.

(b) Check that the EVAP purge port of the throttle body is not clogged. If necessary, replace the throttle body.

NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)

35. REPLACE ECM

(a) Replace the ECM Components.

NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)

36. REPAIR OR REPLACE PARTS AND COMPONENTS INDICATED BY OUTPUT DTCS

(a) Repair the malfunctioning areas indicated by the DTCs that had been confirmed when the vehicle was brought in.

NEXT -- Continue to next step.

37. PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)

NOTICE:
* In the Evaporative System Check (Automatic Mode), the series of 5 Evaporative System Check steps are performed automatically. It takes a maximum of approximately 18 minutes.
* Do not perform the Evaporative System Check when the fuel tank is more than 90% full because the cut-off valve may be closed, making the leak check of the fuel tank unavailable.
* Do not run the engine in this step.
* When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing an Evaporative System Check, keep the temperature below 35°C (95°F).

(a) Clear the DTCs DTC Check / Clear.

(b) On the Techstream, select the following menu items: Powertrain / Engine and ECT / Utility / Evaporative System Check / Automatic Mode.

(c) After the Evaporative System Check is completed, check for pending DTCs by selecting the following menu items: Powertrain / Engine and ECT / Trouble Codes / Pending.

HINT
If no pending DTC is found, the repair has been successfully completed.

NEXT -- COMPLETED
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