Part 2

2GR-FXE ENGINE CONTROL SYSTEM: SFI SYSTEM: EVAP System
- EVAP System - Continued

21. CHECK FUEL TANK CAP ASSEMBLY

(a) Check if the fuel cap is tightened until a few "click" sounds are heard.

(b) If you have the EVAP tester, check the fuel cap using the fuel cap adaptor.

(1) Install the fuel cap to the fuel cap adaptor, and connect the hose from the EVAP tester's pump.

(2) Pressurize the fuel cap adaptor to between 3.2 and 3.7 kPa-g (24 and 28 mmHg-g) or for 45 seconds.

(3) Stop the pump and seal the fuel cap adaptor.

(4) Wait 2 minutes.

(5) Confirm that the pressure is higher than 2.0 kPa-g (15 mmHg-g).

OK:

Higher than 2.0 kPa-g (15 mmHg-g)

NG -- REPLACE FUEL TANK CAP ASSEMBLY
OK -- Continue to next step.

22. CHECK HOSES (FUEL VAPOR-CONTAINMENT VALVE - FUEL TANK)

(a) Remove the canister lower cover.

(b) Connect the pressure gauge to the canister pump module with the adapter.

(c) Connect the Techstream to the DLC3.

(d) Turn the ignition switch to ON.

(e) Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the Fuel Vapor-Containment Valve.

(f) Turn the fuel vapor-containment valve ON using the Techstream.

(g) Pressurize the EVAP system to between 3.2 and 3.7 kPa (24 and 28 mmHg).

NOTICE:
More than 4.7 kPa (35 mmHg) of pressure will damage the EVAP system. Pay attention to the pressure.

(h) Apply soapy water to the piping and connections of the EVAP system. Look for the area where bubbles appear.

HINT
If the system has leaks, a whistling sound will be heard.

(i) Reinstall the canister lower cover.

NEXT -- Continue to next step.

23. CHECK FUEL VAPOR-CONTAINMENT VALVE ASSEMBLY (POWER SOURCE CIRCUIT)

(a) Turn the ignition switch off.

(b) Disconnect the Ok1 connector.

(c) Connect the Techstream to the DLC3.

(d) Turn the ignition switch to ON.

(e) Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the Fuel Vapor-Containment Valve.

(f) Turn the fuel vapor-containment valve ON using the Techstream.

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

Standard Voltage:

Result:

Text in Illustration

(h) Reconnect the connector.

B -- CHECK HARNESS AND CONNECTOR (TANK WIRE HARNESS)
A -- Continue to next step.

24. CHECK HARNESS AND CONNECTOR (FUEL VAPOR-CONTAINMENT VALVE POWER SOURCE)

(a) Disconnect the Ok1 connector.

(b) Turn the ignition switch to ON.

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

Standard Voltage:

Text in Illustration

(d) Reconnect the connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

25. CHECK HARNESS AND CONNECTOR (TANK WIRE HARNESS)

(a) Remove the fuel tank assembly Removal.

(b) Disconnect the Ok1 connector.

(c) Disconnect the fuel vapor-containment valve connector.

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

Standard Resistance:

(e) Reinstall the fuel tank assembly Installation.

Text in Illustration

(f) Reconnect the connectors.

(g) Reinstall the fuel tank assembly

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

26. REPLACE ECM

(a) Replace the ECM Removal.

NEXT -- PERFORM EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC MODE)

27. REPLACE PURGE VSV

(a) Replace the purge VSV Removal.

NEXT -- PERFORM EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC MODE)

28. REPLACE CANISTER

(a) Replace the canister Removal.

NEXT -- PERFORM EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC MODE)

29. CHECK HARNESS AND CONNECTOR (TANK WIRE HARNESS)

(a) Remove the fuel tank assembly Removal.

(b) Disconnect the Ok1 connector.

(c) Disconnect the fuel vapor-containment valve connector.

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

Standard Resistance:

(e) Reinstall the fuel tank assembly Installation.

Text in Illustration

(f) Reconnect the connectors.

(g) Reinstall the fuel tank assembly

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

30. REPLACE FUEL VAPOR-CONTAINMENT VALVE

(a) Replace the fuel vapor-containment valve Removal.

NEXT -- PERFORM EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC MODE)

31. REPLACE FUEL TANK CAP ASSEMBLY

NEXT -- PERFORM EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC MODE)

32. REPAIR OR REPLACE HARNESS OR CONNECTOR

NEXT -- PERFORM EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC MODE)

33. REPAIR OR REPLACE VACUUM HOSE (PURGE VSV - THROTTLE WITH MOTOR BODY ASSEMBLY)

NEXT -- PERFORM EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC MODE)

34. PERFORM EVAPORATIVE SYSTEM CHECK (MANUAL MODE)

HINT
In the manual operation check, the EVAP system can be checked in several steps. Valve operation and pressure in each step can also be checked.

(a) Clear the DTCs Reading and Clearing Diagnostic Trouble Codes.

(b) Remove the fuel tank cap and reinstall the fuel tank cap.

(c) Enter the following menus: Powertrain / Engine and ECT / Utility / Evaporative System Check / Manual Mode.

NOTICE:
* In the Evaporative System Check (Manual Mode), the series of 9 Evaporative System Check steps is 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 impossible.
* 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 the Evaporative System Check, keep the temperature below 35°C (95°F).

Tester Display

Manual Operation Step

NEXT -- Continue to next step.

35. PERFORM EVAPORATIVE SYSTEM CHECK (MANUAL MODE STEP 1)

(a) Select step 1 and wait 10 seconds.

NEXT -- Continue to next step.

36. PERFORM EVAPORATIVE SYSTEM CHECK (MANUAL MODE STEP 2)

(a) Perform step 2.

(b) Check the evaporative pressure 2 seconds after the vacuum pump is activated*. (step b)

*: The vacuum pump begins to operate at the start of step 2.

(c) Check the evaporative (EVAP) pressure again when it has stabilized. This pressure is the first reference pressure standard.

Result:

C -- REPLACE CANISTER

B -- CHECK CANISTER PUMP MODULE (VACUUM PUMP POWER SOURCE CIRCUIT)
A -- Continue to next step.

37. PERFORM EVAPORATIVE SYSTEM CHECK (MANUAL MODE STEP 3)

(a) Perform step 3.

(b) Check the evaporative (EVAP) pressure change in step 3. (step b)

Result:

(d) Check the evaporative pressure again when it has stabilized. This pressure is the canister leak pressure standard.

(e) Compare the first reference pressure with the canister leak pressure.

Result:

D -- CHECK HOSES (PURGE VSV - CANISTER)

C -- CHECK FUEL VAPOR-CONTAINMENT VALVE ASSEMBLY (POWER SOURCE CIRCUIT)

B -- CHECK CANISTER PUMP MODULE (VENT VALVE POWER SOURCE CIRCUIT)
A -- Continue to next step.

38. PERFORM EVAPORATIVE SYSTEM CHECK (MANUAL MODE STEP 4)

(a) Perform step 4.

(b) Check the evaporative (EVAP) pressure change in step 4. (step b)

Result:

B -- CHECK VACUUM HOSE (PURGE VSV - THROTTLE WITH MOTOR BODY ASSEMBLY)
A -- Continue to next step.

39. PERFORM EVAPORATIVE SYSTEM CHECK (MANUAL MODE STEP 5)

(a) Perform step 5 and wait 60 seconds.

(b) Check the evaporative (EVAP) pressure. This pressure is the second reference pressure standard.

NEXT -- Continue to next step.

40. PERFORM EVAPORATIVE SYSTEM CHECK (MANUAL MODE STEP 6)

(a) Perform step 6 and wait 5 seconds.

NEXT -- Continue to next step.

41. PERFORM EVAPORATIVE SYSTEM CHECK (MANUAL MODE STEP 7)

(a) Perform step 7.

(b) Check that the tank pressure and EVAP pressure change.

(c) Check the tank pressure again when it has stabilized. This pressure is the fuel tank leak pressure standard.

Result:

B -- CHECK FUEL VAPOR-CONTAINMENT VALVE ASSEMBLY (POWER SOURCE CIRCUIT)
A -- Continue to next step.

42. PERFORM EVAPORATIVE SYSTEM CHECK (MANUAL MODE STEP 8)

(a) Perform step 8 and wait 60 seconds.

(b) Check the evaporative (EVAP) pressure. This pressure is the third reference pressure standard.

(c) Compare the tank pressure checked in step 41 with the third reference pressure.

Result:

B -- CHECK FUEL TANK CAP ASSEMBLY
A -- Continue to next step.

43. PERFORM CONFIRMATION DRIVING PATTERN

(a) KEY-OFF MONITOR DRIVE PATTERN

(1) Connect the Techstream to the DLC3.

(2) Confirm the following conditions are satisfied:

- The fuel level is less than 90%.
- The altitude is less than 7874 ft. (2400 m).
- The vehicle is stopped (the vehicle speed is less than 2 mph).
- The engine coolant temperature is 4.4 to 35°C (40 to 95°F)
- The intake air temperature is 4.4 to 35°C (40 to 95°F)

(3) Perform the following drive pattern:

- Allow the engine to idle for 5 minutes or more.
- Turn the ignition switch off and wait 6 hours.

(4) Check the monitor status with the Techstream.

(b) PURGE FLOW MONITOR DRIVE PATTERN (P0441)

(1) Connect the Techstream to the DLC3.

(2) Confirm that the following conditions are satisfied:

- The engine coolant temperature is more than 4.4°C (40°F).
- The intake air temperature is more than 4.4°C (40°F).

(3) Perform the following drive pattern:

- Remove and reinstall the fuel cap to release the fuel tank pressure.
- Warm up the engine until the engine coolant temperature reaches 75°C (167°F) or more.
- Run the engine at 3000 rpm once.

(4) Check the monitor status with the Techstream.

NEXT -- PERFORM EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC MODE)

44. CHECK VACUUM HOSE (PURGE VSV - THROTTLE WITH MOTOR BODY ASSEMBLY)

(a) Disconnect the hose (to the intake air connector) from the purge VSV.

(b) Start the engine.

(c) Use your finger and confirm that the purge VSV has suction.

Text in Illustration

Result:

(d) Reconnect the hose.

NG -- REPAIR OR REPLACE VACUUM HOSE (PURGE VSV - THROTTLE WITH MOTOR BODY ASSEMBLY)
OK -- Continue to next step.

45. PERFORM ACTIVE TEST USING TECHSTREAM (PURGE VSV)

(a) Enter the following menus: Powertrain / Engine and ECT / Active Test / Active the VSV for EVAP Control.

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

Text in Illustration

(c) Start the engine.

(d) Using the Techstream, turn off the purge VSV (Activate the VSV for Evap Control: OFF).

(e) Use your finger to confirm that the purge VSV has no suction.

(f) Using the Techstream, turn on the purge VSV (Activate the VSV for Evap Control: ON).

(g) Use your finger to confirm that the purge VSV has suction.

Result:

(h) Reconnect the hose.

B -- CHECK HOSES (PURGE VSV - CANISTER)
A -- Continue to next step.