Toyota TUNDRA 2004 Reference manual

Toyota Supports ASE Certification Page 1 of 41
EG048-04
Title:
REPAIR MANUAL SUPPLEMENT:
LEV II EVAP SYSTEM CHECK -
DTC P0441, P0442, P0446, P0451,
P0452, P0453, P0455 & P0456
Models:
’03 -- ’04 4Runner & Tundra, ’04 Camry, Highlander,
Sienna & Solara
Technical Service
BULLETIN
November 12, 2004
This TSB provides detailed instructions for a new LEV II EVAP System Check function
using the Diagnostic Tester.
The LEV II System Check allows the Diagnostic Tester to display the fuel tank vapor
pressure as the EVAP VSV and the CCV are operated in a specific six--step pattern.
Problems with the EVAP system are quickly isolated by observing the change in vapor
pressure during each step.
Once the vehicle condition is corrected, the LEV II System Check can also be used to
confirm the repair before the vehicle is returned to the customer.
The inspection procedure using the LEV II System Check (LEV II SYS CHECK) is
described in this bulletin. This function is available using a Diagnostic Tester with version
11.0a software (or newer).
S2003 -- 2004 model year 4Runner vehicles equipped with 2UZ--FE and
1GR--FE engines.
S2003 -- 2004 model year Tundra vehicles equipped with 5VZ--FE and
2UZ--FE engines.
S2004 model year Camry vehicles equipped with 2AZ--FE, 1MZ--FE and
3MZ--FE engines.
S2004 model year Highlander and Sienna vehicles equipped with 3MZ--FE engine.
S2004 model year Solara vehicles equipped with 2AZ--FE and 3MZ--FE engines.
SECTION TITLE PAGE
ALEV II SYS CHECK Description 3
BDTC Check 4
CLEV II SYS CHECK (Diagnostic Tester System Test) 5
DAir Inlet Restriction Inspection 13
EEVAP VSV Stuck--Open Inspection 16
FLeak Check or No Vacuum Drawn on System Inspection 17
GCCV Diagnostics 22
HEVAP VSV Diagnostics 25
IEVAP System Description 30
JEVAP System DTC Descriptions 33
KEVAP Monitor Description 35
LOBD II EVAP Monitor Specifications 39
OP CODE DESCRIPTION TIME OFP T1 T2
N/A Not Applicable to Warranty – – – –
ENGINE
Introduction
A
pplicable
Vehicles
Table of
Contents
Warranty
Information

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 2 of 41
SPECIAL SERVICE TOOLS (SSTs) PART NUMBER QUANTITY
Toyota Diagnostic Tester Kit* 01001271 1
12 Megabyte Diagnostic Tester Program Card
with version 11.0a Software (or later)* 01002593-005 1
EVAP Tester Kit* 00002--6872A 1
EVAP Tester Fuel Cap Adapter*
00002--6872A--FC
or
00002--6872A--FCA
1
* Essential SSTs.
NOTE:
Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by
calling SPX/OTC at 1-800-933-8335.
TERM DEFINITION
CCV Evaporative Emissions Canister Control Valve
Charcoal Canister Evaporative Emissions Canister
DTC(s) Diagnostic Trouble Code(s)
ECM (SAE term: PCM) Engine Control Module (SAE term: Powertrain Control Module)
ECT Engine Coolant Temperature
EVAP Evaporative Emissions
EVAP VSV, Purge VSV Evaporative Emissions Canister Purge Valve
FTP Fuel Tank Pressure
IAT Intake Air Temperature
LEV II Low Emissions Vehicle Phase 2
MIL Malfunction Indicator Lamp
mmHg--a Unit of Absolute Pressure (762 mmHg--a at sea level)
mmHg--g Unit of Gauge Pressure (0 mmHg--g at sea level)
Vapor Pressure Sensor Fuel Tank Pressure Sensor
Required
SSTs
Terms &
Definitions

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 3 of 41
The LEV II System Check allows the Diagnostic Tester to display the fuel tank vapor
pressure as the EVAP VSV and the CCV are operated in a specific six--step pattern.
Problems with the EVAP system are quickly isolated by observing the change in vapor
pressure during each step.
Detail of “LEV II SYS CHECK”
Step 1
System Check Steps Step 2 Step 3 Step 4 Step 5 Step 6
CCV
(Normally Open)
EVAP VSV
(Normally Closed)
Required Time 30 sec 15 sec 30 sec 300 sec
Ambient
Pressure
CLOSED
OPEN
OPEN OPEN
CLOSED
CLOSED
Large Leak
System Line Restriction
CCV Stuck Open
EVAP VSV Stuck Closed
Medium Leak
Small Leak
CCV Stuck Closed
Air Inlet Line Restriction
Medium
Leak
CCV Stuck
Open
NOTE:
The EVAP system pressure can be affected by ambient temperature, atmospheric
pressure, and fuel level. This test is most accurate when the following conditions
are met.
SThe vehicle is at sea level and at an atmospheric pressure of approximately
762 mmHg--a (0 mmHg--g).
SThe external fuel tank temperature is between 4 to 35_C (40 to 90_F).
SThe fuel level in the fuel tank is approximately 1/4 to 3/4 full.
A
.LE
V
II
SYS CHECK
Description

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 4 of 41
Check for current and pending DTCs to determine which part of the
EVAP system may be malfunctioning.
1
A. Connect the Diagnostic Tester to DLC3.
B. Enter the following menus:
DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING DTCS.
C. Enter the following menus:
DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT DTCS.
D. Make a note of any pending and/or current DTCs.
RESULT:
DTC GO TO
P0441, P0442, P0446, P0455 and/or P0456 A
P0451, P0452 or P0453 B
A
B
Check vapor pressure sensor
(refer to Repair Manual in the Technical
Information System [TIS]: Diagnostics:
SFI System: DTC P0451, P0452, or P0453
Go to Step 1 of “C: LEV II SYS CHECK”
(page 5).
B. DTC Chec
k

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 5 of 41
1Pressure Equalize
In Step 1, the EVAP actuators are at rest and the system pressure should equalize with
outside atmospheric pressure. This step ensures the test starts without any vacuum
and/or pressure on the system.
Order
EVAP VSV
CCV
VAPOR
PRESS
EVAP Pressure Change During System Check
Positive
Negative
Normal
Step 1. Pressure Equalize
Step 1
Closed
Open
EVAP VSV: Closed
(Normally Closed)
CCV: Open
(Normally Open)
Vapor Pressure
Sensor
A. Start the engine.
B. Enter the following menus:
DIAGNOSIS / ENHANCED
OBD ll / SYSTEM CHECK /
LEV ll SYS CHECK.
C. Read the vapor pressure sensor
value (VAPOR PRESS).
D. Vapor Pressure should equalize
with the atmosphere within
30 seconds.
Continue to the next step when
pressure is 760 to 764 mmHg--a
(--2 to 2 mmHg--g).
NEXT
Press the right arrow key on the
Diagnostic Tester to go to the
next step.
C. LE
V
II S
Y
S
CHECK
LEVII SYSTEM CHECK
Step 1. Pressure Equalize
EVAP VSV CLOSE......
CCV OPEN.............
VAPOR PRESS
762 mmHg--a....
Time 030 seconds
Press [RIGHT]
Sample Screen

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 6 of 41
2Purge w/CCV Open
During Step 2, while the engine is running, the ECM (PCM) energizes/de--energizes
(duty cycles) the EVAP VSV and a vacuum is applied to the entire system. The LEV ll
system uses a high flow CCV. Since the CCV is open, there should be little or no drop in
system pressure.
Normal (OK)
Step 2
Open
Open
Order
EVAP VSV
CCV
VAPOR
PRESS
EVAP Pressure Change During System Check
Positive
Negative
Step 2. Purge w/CCV Open
EVAP VSV: Open
(Normally Closed)
CCV: Open
(Normally Open)
Vapor Pressure
Sensor
CCV Stuck
Closed
(NG)
CHECK:
Wait for 30 seconds. Read the vapor
pressure sensor value
(VAPOR PRESS).
VAPOR PRESS VALUE CONCLUSION GO TO
753 to 762 mmHg--a (--9 to 0 mmHg--g) No trouble found in this step OK
732 to 752 mmHg--a (--30 to --10 mmHg--g) CCV stuck closed or air inlet line restriction NG
OK NG Go to “D. Air Inlet Restriction
Inspection” (page 13).
Press the right arrow key to go to
the next step.
C. LE
V
II S
Y
S
CHECK
(Continued)
Sample Screen
LEVII SYSTEM CHECK
Step 2. Purge w/CCV
Open
EVAP VSV OPEN.......
CCV OPEN.............
VAPOR PRESS
761 mmHg--a....
Time 030 seconds
Press [RIGHT]

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 7 of 41
3Pressure Equalize
During Step 3, the ECM (PCM) closes the EVAP VSV shutting off vacuum to the system.
The CCV remains open, therefore allowing fresh air into the system. The system should
equalize to atmosphere within 30 seconds.
Normal
Step 3
Closed
Open
Order
EVAP VSV
CCV
VAPOR
PRESS
EVAP Pressure Change During System Check
Positive
Negative
Step 3. Pressure Equalize
EVAP VSV: Closed
(Normally Closed)
CCV: Open
(Normally Open)
Vapor Pressure
Sensor
A. Read the vapor pressure sensor
value (VAPOR PRESS).
B. The vapor pressure value should
be 760 to 764 mmHg--a
(--2 to 2 mmHg--g) (equal to
ambient pressure) within
30 seconds.
C. Continue to the next step.
NEXT
Press the right arrow key to go to
the next step.
C. LE
V
II S
Y
S
CHECK
(Continued)
LEVII SYSTEM CHECK
Step 3. Pressure Equalize
EVAP VSV CLOSE......
CCV OPEN.............
VAPOR PRESS
762 mmHg--a....
Time 030 seconds
Press [RIGHT]
Sample Screen

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 8 of 41
4Sealing System
During step 4, the CCV is closed and the system is sealed. Since the EVAP VSV is
closed, there should be no drop in system pressure.
Normal (OK)
Step 4
Closed
Closed
Order
EVAP VSV
CCV
VAPOR
PRESS
EVAP Pressure Change During System Check
Positive
Negative
Step 4. Sealing System
EVAP VSV: Closed
(Normally Closed)
CCV: Closed
(Normally Open)
Vapor Pressure
Sensor
EVAP VSV
Stuck Open
(NG)
CHECK:
Wait 15 seconds and check the vapor
pressure sensor value (VAPOR PRESS).
VAPOR PRESS VALUE CONCLUSION GO TO
758 to 768 mmHg--a (--4 to 6 mmHg--g) No trouble found in this step OK
732 to 757 mmHg--a (--30 to --5 mmHg--g) EVAP VSV stuck open NG
OK NG Go to “E. EVAP VSV Stuck--Open
Inspection” (page 16)
Press the right arrow key to go to
the next step.
C. LE
V
II S
Y
S
CHECK
(Continued)
LEVII SYSTEM CHECK
Step 4. Sealing System
EVAP VSV CLOSE......
CCV CLOSE............
VAPOR PRESS
762 mmHg--a....
Time 015 seconds
Press [RIGHT]
Sample Screen

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 9 of 41
5Applying Vacuum
During step 5, vacuum is applied to the EVAP system. The fuel tank’s interior should
develop negative pressure within 30 seconds (see example “A” in the diagram below).
If the pressure does not decrease sufficiently within 30 seconds, (for example, “B” in
diagram below) this indicates a leak or restriction in the system.
A moderate drop in pressure (for example, “C” in diagram below) indicates that a medium
leak is occurring in the system.
Normal
Step 5
Open
Closed
Medium
Leak
Order
EVAP VSV
CCV
VAPOR
PRESS
EVAP Pressure Change During System Check
Positive
Negative
Step 5. Applying Vacuum
EVAP VSV: Open
(Normally Closed)
CCV: Closed
(Normally Open)
Vapor Pressure
Sensor
C
B
A
1. Large Leak
2. System Line Restriction
3. CCV Stuck Open
4. EVAP VSV Stuck Closed
CHECK:
Wait for 30 seconds. Read the vapor
pressure sensor value (VAPOR PRESS).
NOTE:
Fuel level should be between 1/4 to 3/4
of a tank for proper vacuum testing.
NOTE:
SIf the pressure drops to 740 mmHg--a (--22 mmHg--g) at any point during this test,
the Diagnostic Tester will close the EVAP VSV to prevent system damage.
OR:
SIf the pressure drops to 735 mmHg--a (--27 mmHg--g) the Diagnostic Tester will abort
the LEV II SYS CHECK.
This usually happens when the fuel level in the tank is above 3/4 full.
Recheck proper fuel level, then restart the LEV II SYS CHECK.
C. LE
V
II S
Y
S
CHECK
(Continued)
LEVII SYSTEM CHECK
Step 5. Applying vacuum
EVAP VSV OPEN.......
CCV CLOSE............
VAPOR PRESS
740 mmHg--a....
Time 030 seconds
Press [RIGHT]
Sample Screen

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 10 of 41
VAPOR PRESS VALUE CONCLUSION GO TO
732 to 742 mmHg--a (--30 to --20 mmHg--g) No trouble found in this step A
743 to 768 mmHg--a (--19 to 6 mmHg--g)
Medium to large leak, EVAP line restriction,
EVAP VSV stuck closed or CCV
stuck open
B
B
Go to “F. Leak Check or No Vacuum
Drawn on System Inspection”
(page 17).
A
Press the right arrow key to go to
the next step.
C. LE
V
II S
Y
S
CHECK
(Continued)

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 11 of 41
6Sealing Vacuum
During step 6, the EVAP system is sealed and the change in fuel tank interior pressure
is monitored.
Step 6
Closed
Closed
Small Leak (NG)
Order
EVAP VSV
CCV
VAPOR
PRESS
EVAP Pressure Change During System Check
Positive
Negative
Step 6. Sealing Vacuum
EVAP VSV: Closed
(Normally Closed)
CCV: Closed
(Normally Open)
Vapor Pressure
Sensor
Normal (OK)
Very Small Leak
(NG)
CHECK:
Wait 300 seconds (5 minutes) and check
the vapor pressure.
VAPOR PRESS VALUE CONCLUSION GO TO
732 to 758 mmHg--a (--30 to --4 mmHg--g) No trouble found in this step OK
759 to 768 mmHg--a (--3 to 6 mmHg--g) Small leak or very small leak NG
OK NG Go to “F. Leak Check or No Vacuum
Drawn on System Inspection”
(page 17).
C. LE
V
II S
Y
S
CHECK
(Continued)
LEVII SYSTEM CHECK
Step 6. Sealing Vacuum
EVAP VSV CLOSE......
CCV CLOSE............
VAPOR PRESS
752 mmHg--a....
Time 300 seconds
Press [RIGHT]
Sample Screen

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 12 of 41
No leak detected and VSV operation is normal.
Before returning the vehicle to the customer, perform the following:
A. Clear all DTCs.
B. Perform a drive pattern test and confirm that no pending DTCs are recorded.
C. Make sure the monitors pass.
C. LE
V
II S
Y
S
CHECK
(Continued)

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 13 of 41
NOTE:
Before starting this procedure, perform the “LEV II SYS CHECK” (see page 5).
1Perform CCV Active Test using the Diagnostic Tester.
PREPARATION:
A. Turn the ignition switch ON.
B. Enter the following menus:
DIAGNOSIS / ENHANCED
OBD ll / ACTIVE TEST /
CAN CTRL VSV.
C. Then press the right or left
arrow key to activate the CCV.
CHECK:
Operate the CCV through the ACTIVE
TEST and touch the CCV with your hand.
Check that the motion of the valve inside
theCCVcanbefelt.
OK:
Motion of valve inside CCV can be felt.
OK NG Go to “G. CCV Diagnostics”
(see step 2 on page 22).
2Determine source of air flow restriction.
PREPARATION:
A. Turn off the engine.
B. Disconnect the air inlet line
from CCV.
C. Remove and reinstall fuel tank
cap to release system pressure.
D. Restart the engine.
D. Air Inlet
Restriction
Inspection
Feel Motion of Valve Inside CCV
Fuel Tank
Charcoal
Canister Filter
Disconnect
CCV
Charcoal Canister
EVAP VSV

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 14 of 41
E. Enter the following menus:
DIAGNOSIS / ENHANCED
OBD ll / SYSTEM CHECK /
LEV ll SYS CHECK.
F. Advance to “Step 2. Purge
w/CCV Open.”
CHECK:
A. After waiting 30 seconds, check
the vapor pressure sensor value.
B. Reconnect the air inlet line to CCV.
VAPOR PRESS VALUE CONCLUSION GO TO
732 to 751 mmHg--a (--30 to --11 mmHg--g) A restriction is present in the CCV, or the
charcoal canister. A
752 to 762 mmHg--a (--10 to 0 mmHg--g) A restriction is present in either the air inlet
line or canister filter. B
A
BReplace Charcoal Canister Filter
and repeat Active Test “LEV II SYS
CHECK” to verify proper system
operation (see page 5).
3Determine if air flow restriction is in CCV or the charcoal canister.
PREPARATION:
A. Turn OFF the engine.
B. Remove the CCV from the
charcoal canister.
C. Remove and reinstall fuel tank
cap to release system pressure.
D. Restart the engine.
D. Air Inlet
Restriction
Inspection
(Continued)
LEVII SYSTEM CHECK
Step 2. Purge w/CCV
Open
EVAP VSV OPEN.......
CCV OPEN.............
VAPOR PRESS
761 mmHg--a....
Time 030 seconds
Press [RIGHT]
Sample Screen
Charcoal Canister
EVAP VSV
Fuel Tank
Charcoal
Canister Filter
Remove
CCV

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 15 of 41
E. Enter the following menus:
DIAGNOSIS / ENHANCED
OBD ll / SYSTEM CHECK /
LEV ll SYS CHECK.
F. Advance to “Step 2. Purge
w/CCV Open.”
CHECK:
A. After waiting 30 seconds, check
the vapor pressure sensor value.
B. Reconnect the air inlet line to
charcoal canister filter.
VAPOR PRESS VALUE CONCLUSION GO TO
752 to 762 mmHg--a (--10 to 0 mmHg--g) CCV is stuck closed. A
732 to 751 mmHg--a (--30 to --11 mmHg--g) A restriction is present in the
charcoal canister. B
A
B
Replace charcoal canister, and repeat
Active Test “LEV ll SYS CHECK”
to verify proper system operation
(see page 5).
Go to “G. CCV Diagnostics” (see step 2 on page 22).
D. Air Inlet
Restriction
Inspection
(Continued)
LEVII SYSTEM CHECK
Step 2. Purge w/CCV
Open
EVAP VSV OPEN.......
CCV OPEN.............
VAPOR PRESS
761 mmHg--a....
Time 030 seconds
Press [RIGHT]
Sample Screen

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 16 of 41
NOTE:
Before starting this procedure, perform the “LEV II SYS CHECK” (see page 5).
1Determine if stuck--open EVAP malfunction is electrical or mechanical.
PREPARATION:
A. Advance to “Step 4.
Sealing System.”
B. Disconnect the EVAP VSV
electrical connector.
HINT:
The EVAP VSV is normally closed.
If the EVAP VSV is functioning
normally, disconnecting the VSV
connector will keep the VSV closed.
C. Wait 30 seconds.
D. Check the vapor pressure sensor value.
E. Remove and reinstall fuel tank cap to release system pressure.
VAPOR PRESS VALUE CONCLUSION GO TO
732 to 751 mmHg--a (--30 to --11 mmHg--g) EVAP VSV is stuck open. A
752 to 762 mmHg--a (--10 to 0 mmHg--g) EVAP VSV circuit has a malfunction. B
AB
Reconnect EVAP VSV electrical
connector. Go to “H. EVAP VSV
Diagnostics” (page 25).
Replace EVAP VSV and repeat “LEV ll SYS CHECK” to verify proper system
operation (page 5).
E. EVAP VSV
Stuck--Open
Inspection
LEVII SYSTEM CHECK
Step 4. Sealing System
EVAP VSV CLOSE......
CCV CLOSE............
VAPOR PRESS
762 mmHg--a....
Time 015 seconds
Press [RIGHT]
Sample Screen

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 17 of 41
NOTE:
Before starting this procedure, perform the “LEV II SYS CHECK” (see page 5).
1Check that fuel tank cap is correctly installed.
CHECK:
A. Check that the fuel tank cap is
correctly installed.
B. Check that the fuel tank cap
meets OEM specifications.
C. Check that the fuel tank cap and
fuel tank cap gasket are not
damaged.
OK:
Fuel tank cap is properly fastened and
meets OEM specification.
HINT:
SWhen using EVAP Tester Fuel Cap Adapter:
Use the Fuel Cap Adapter to check if pressure is leaking as a result of the fuel
tank cap.
SIf the fuel tank cap is not properly fastened, the EVAP system will be unable to
maintain enough negative pressure (vacuum). The ECM (PCM) may interpret the
pressure leak as a system malfunction and set a DTC.
SFor each step in the LEV ll SYS CHECK, the vapor pressure sensor should be within
the given standard values.
OK NG Correctly install fuel tank cap. Restart
LEV II SYS CHECK (see page 5).
F. Leak Check
or No Vacuum
Drawn on
System
Inspection
EVAP Tester Fuel Cap Adapter
(P/N 00002--6872A--FC or
00002--6872A--FCA)
EVAP Tester Kit
(P/N 00002--6872A)

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 18 of 41
2Check for filler neck damage.
PREPARATION:
Remove the fuel tank cap.
CHECK:
Visually inspect the filler neck for
damage.
OK:
No damage
Reinstall the fuel tank cap.
OK NG Replace fuel tank inlet pipe
(filler neck).
3Confirm EVAP VSV will open.
HINT:
The EVAP Pressure Tester Gauge Kit is useful for detecting when the EVAP VSV is
stuck closed.
Check EVAP VSV Operation.
A. Connect the EVAP Pressure
Tester Gauge (EVAP control
system test equipment vacuum
gauge) to the EVAP service port
on the purge line.
B. Start the engine.
C. Enter the following menus:
DIAGNOSIS / ENHANCED
OBD ll / ACTIVE TEST / EVAP VSV.
D. Activate the EVAP VSV through
the ACTIVE TEST. Read the
pressure gauge and check that
negative pressure is present.
F. Leak Check
or No Vacuum
Drawn on
System
Inspection
(Continued)
EVAP Pressure Tester Gauge Kit
(P/N 00002--6872A)
EVAP Pressure Tester Gauge

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 19 of 41
VAPOR PRESS VALUE CONCLUSION GO TO
732 to 761 mmHg--a (--1 to --30 mmHg--g) EVAP VSV is functioning properly. OK
762 mmHg--a (0 mmHg--g) No negative pressure or pulsation.
EVAP VSV is stuck closed. NG
OK
NG
If no negative pressure or pulsation
is present, the EVAP VSV is most
likely stuck closed.
Proceed to “H. EVAP VSV
Diagnostics” (page 25).
4Check for EVAP leak using the EVAP Tester Kit.
CAUTION:
Do not add more than 797 mmHg--a (35 mmHg--g) of pressure.
The EVAP system will be damaged.
CHECK:
A. Ignition switch is ON but the
engine is not running.
B. Enter the following menus:
DIAGNOSIS / ENHANCED OBD ll /
ACTIVE TEST / CAN CTRL VSV.
Press the right arrow key.
C. Close the CCV (CCV is ON).
D. From the EVAP service port, apply
786 to 790 mmHg--a
(24 to 28 mmHg--g) of pressure.
Do not apply pressure continuously
for more than 45 seconds.
Once pressure is added, maintain
the pressure and seal the system.
E. After waiting 2 minutes, read
the pressure gauge and record
the values.
NG OK System is operating normally.
F. Leak Check
or No Vacuum
Drawn on
System
Inspection
(Continued)
EVAP Tester Kit
(P/N 00002--6872A)

REPAIR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Page 20 of 41
5Check hose and tubes between EVAP VSV and charcoal canister,
and fuel tank and charcoal canister.
CHECK:
A. Check that the vacuum hoses are
connected correctly.
B. Check that the vacuum hoses are
not loose or disconnected.
C. Check the vacuum hoses and
tubes for cracks, holes, damage,
or blockage.
OK NG Repair or replace defective or
damaged hose or tube.
6Eliminate CCV as source of leakage by clamping air inlet line between the
charcoal canister filter and the CCV.
CHECK:
A. Ignition switch is ON but the
engine is not running.
B. Enter the following menus:
DIAGNOSIS / ENHANCED OBD ll /
ACTIVE TEST / CAN CTRL VSV.
Press the right arrow key.
C. Close the CCV (CCV is ON).
D. From the EVAP service port, apply 786 to 790 mmHg--a (24 to 28 mmHg--g) of
pressure. Do not apply pressure continuously for more than 45 seconds. Once
pressure is added, maintain the pressure and seal the system.
E. After waiting 2 minutes, read the pressure gauge and record the values.
Check that the CCV is not stuck open and does not have leakage.
VAPOR PRESS VALUE CONCLUSION GO TO
762 mmHg--a (0 mmHg--g) CCV is not leaking. OK
786 to 790 mmHg--a (24 to 28 mmHg--g) Positive pressure increase. CCV open. NG
OK NG
If positive pressure is present, the
CCV is not closing. Proceed to
“G. CCV Diagnostics” (page 22).
F. Leak Check
or No Vacuum
Drawn on
System
Inspection
(Continued)
EVAP Tester Kit
(P/N 00002--6872A)