Sienna 2004
Technical Service
A
BULLETIN
November 12, 2004
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
ENGINE
EG048-04
Introduction
pplicable
Vehicles
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).
S 2003 -- 2004 model year 4Runner vehicles equipped with 2UZ--FE and
1GR--FE engines.
S 2003 -- 2004 model year Tundra vehicles equipped with 5VZ--FE and
2UZ--FE engines.
S 2004 model year Camry vehicles equipped with 2AZ--FE, 1MZ--FE and
3MZ--FE engines.
S 2004 model year Highlander and Sienna vehicles equipped with 3MZ--FE engine.
S 2004 model year Solara vehicles equipped with 2AZ--FE and 3MZ --FE engines.
Tab l e of
Contents
Warranty
Information
T oyota Supports ASE Certification
SECTION TITLE PAGE
OP CODE DESCRIPTION TIME OFP T1 T2
N/A Not Applicable to Warranty – – – –
A LEV II SYS CHECK Description 3
B DTC Check 4
C LEV II SYS CHECK (Diagnostic Tester System Test) 5
D Air Inlet Restriction Inspection 13
E EVAP VSV Stuck--Open Inspection 16
F Leak Check or No Vacuum Drawn on System Inspection 17
G CCV Diagnostics 22
H EVAP VSV Diagnostics 25
I EVAP System Description 30
J EVAP System DTC Descriptions 33
K EVAP Monitor Description 35
L OBD II EVAP Monitor Specifications 39
Page 1 of 41
REP A IR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
Required
SSTs
SPECIAL SERVICE TOOLS (SSTs) PART NUMBER QUANTITY
Toyota Diagnostic Tester Kit*
12 Megabyte Diagnostic Tester Program Card
with version 11.0a Software (or later)*
EVAP Tester Kit*
01001271 1
01002593-005 1
00002--6872A 1
00002--6872A--FC
EVAP Tester Fuel Cap Adapter*
or
00002--6872A--FCA
* Essential SSTs.
NOTE:
Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by
calling SPX/OTC at 1-800-933-8335.
1
Terms &
Definitions
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
Page 2 of 41
REP A IR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
A
.LEVII
SYS CHECK
Description
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”
System Check Steps
(Normally Open)
EVAP VSV
(Normally Closed)
Required Time
Ambient
Pressure
Step 1
CCV
CLOSED
Step 2 Step 3 Step 4 Step 5 Step 6
OPEN
OPEN OPEN
30 sec 15 sec 30 sec 300 sec
CLOSED
CLOSED
CCV Stuck Closed
Air Inlet Line Restriction
CCV Stuck
Open
Large Leak
System Line Restriction
CCV Stuck Open
EVAP VSV Stuck Closed
Medium
Leak
Medium Leak
Small Leak
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.
S The vehicle is at sea level and at an atmospheric pressure of approximately
762 mmHg--a (0 mmHg--g).
S The external fuel tank temperature is between 4 to 35_C (40 to 90_F).
S The fuel level in the fuel tank is approximately 1/4 to 3/4 full.
Page 3 of 41
REP A IR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
k
B. DTC Chec
1
Check for current and pending DTCs to determine which part of the
EVAP system may be malfunctioning.
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
Check vapor pressure sensor
B
A
(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).
Page 4 of 41
REP A IR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
C. LEVII SYS
CHECK
1
Pressure 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.
Step 1. Pressure Equalize
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).
Order
EVAP VSV
CCV
VAP OR
PRESS
EVAP Pressure Change During System Check
Step 1
Closed
Open
Normal
Positive
Negative
LEVII SYSTEM CHECK
Step 1. Pressure Equalize
EVAP VSV CLOSE......
CCV OPEN.............
VAPOR PRESS
762 mmHg -- a....
Time 030 seconds
Press [RIGHT]
Sample Screen
NEXT
Press the right arrow key on the
Diagnostic Tester to go to the
next step.
Page 5 of 41
REP A IR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
C. LEVII SYS
CHECK
(Continued)
2
Purge 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.
Step 2. Purge w/CCV Open
EVAP VSV: Open
(Normally Closed)
CCV: Open
(Normally Open)
Vapor Pressure
Sensor
CHECK:
Wait for 30 seconds. Read the vapor
pressure sensor value
(VAPOR PRESS).
Order
EVAP VSV
CCV
VAP OR
PRESS
EVAP Pressure Change During System Check
Step 2
Open
Open
Normal (OK)
CCV Stuck
Closed
(NG)
LEVII SYSTEM CHECK
Step 2. Purge w/CCV
Open
EVAP VSV OPEN.......
CCV OPEN.............
Positive
Negative
Page 6 of 41
VAPOR PRESS
Time 030 seconds
VAPOR PRESS VALUE CONCLUSION GO TO
761 mmHg -- a....
Press [RIGHT]
Sample Screen
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.
REP A IR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
C. LEVII SYS
CHECK
(Continued)
3
Pressure 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.
Step 3. Pressure Equalize
EVAP Pressure Change During System Check
EVAP VSV: Closed
(Normally Closed)
Vapor Pressure
Sensor
Order
EVAP VSV
CCV
Step 3
Closed
Open
CCV: Open
(Normally Open)
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
VAP OR
PRESS
Positive
Negative
Normal
LEVII SYSTEM CHECK
Step 3. Pressure Equalize
EVAP VSV CLOSE......
CCV OPEN.............
VAPOR PRESS
762 mmHg -- a....
Time 030 seconds
Press [RIGHT]
Sample Screen
Press the right arrow key to go to
the next step.
Page 7 of 41
REP A IR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
C. LEVII SYS
CHECK
(Continued)
4
Sealing 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.
Step 4. Sealing System
EVAP VSV: Closed
(Normally Closed)
CCV: Closed
(Normally Open)
Vapor Pressure
Sensor
EVAP VSV
CHECK:
Wait 15 seconds and check the vapor
pressure sensor value (VAPOR PRESS).
EVAP Pressure Change During System Check
Order
CCV
Normal (OK)
VAP OR
PRESS
EVAP VSV
Stuck Open
(NG)
EVAP VSV CLOSE......
CCV CLOSE............
Step 4
Closed
Closed
LEVII SYSTEM CHECK
Step 4. Sealing System
Positive
Negative
VAPOR PRESS
Time 015 seconds
VAPOR PRESS VALUE CONCLUSION GO TO
762 mmHg -- a....
Press [RIGHT]
Sample Screen
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.
Page 8 of 41
REP A IR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
V
C. LE
CHECK
(Continued)
II SYS
5
Applying 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.
Step 5. Applying Vacuum
EVAP VSV: Open
(Normally Closed)
Vapor Pressure
Sensor
EVAP VSV
VAP OR
PRESS
EVAP Pressure Change During System Check
1. Large Leak
B
2. System Line Restriction
3. CCV Stuck Open
4. EVAP VSV Stuck Closed
Order
CCV
Step 5
Open
Closed
Positive
Negative
CCV: Closed
(Normally Open)
A
Normal
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:
S If the pressure drops to 740 mmHg--a (--22 mmHg--g) at any point during this test,
the Diagnostic Tester will close
OR:
S If 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.
the EVAP VSV to prevent system damage.
LEVII SYSTEM CHECK
Step 5. Applying vacuum
EVAP VSV OPEN.......
CCV CLOSE............
VAPOR PRESS
740 mmHg -- a....
Time 030 seconds
Press [RIGHT]
Sample Screen
C
Medium
Leak
Page 9 of 41
REP A IR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
C. LEVII SYS
CHECK
(Continued)
VAPOR PRESS VALUE CONCLUSION GO TO
732 to 742 mmHg--a (--30 to --20 mmHg--g) No trouble found in this step A
Medium to large leak, EVAP line restriction,
743 to 768 mmHg--a (--19 to 6 mmHg--g)
EVAP VSV stuck closed or CCV
stuck open
Go to “F. Leak Check or No Vacuu m
A
B
Drawn on System Inspectio n ”
(page 17).
Press the right arrow key to go to
the next step.
B
Page 10 of 41
REP A IR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
C. LEVII SYS
CHECK
(Continued)
Sealing Vacuum
6
During step 6, the EVAP system is sealed and the change in fuel tank interior pressure
is monitored.
Step 6. Sealing Vacuum
EVAP VSV: Closed
(Normally Closed)
CCV: Closed
(Normally Open)
Vapor Pressure
Sensor
EVAP VSV
CHECK:
Wait 300 seconds (5 minutes) and check
the vapor pressure.
EVAP Pressure Change During System Check
Order
CCV
VAP OR
PRESS
Small Leak (NG)
Very Small Leak
(NG)
LEVII SYSTEM CHECK
Step 6. Sealing Vacuum
EVAP VSV CLOSE......
CCV CLOSE............
Step 6
Closed
Closed
Positive
Negative
Normal (OK)
VAPOR PRESS
Time 300 seconds
VAPOR PRESS VALUE CONCLUSION GO TO
752 mmHg -- a....
Press [RIGHT]
Sample Screen
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).
Page 11 of 41
REP A IR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
C. LEVII SYS
CHECK
(Continued)
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.
Page 12 of 41
REP A IR MANUAL SUPPLEMENT: LEV II EVAP SYSTEM CHECK -- EG048-04 November 12, 2004
D. Air Inlet
Restriction
Inspection
NOTE:
Before starting this procedure, perform the “LEV II SYS CHECK” (see page 5).
1
Perform CCV Active Test using the Diagnostic Tester.
PREPARATION:
A. Turn the ignition switch ON.
Feel Motion of Valve Inside CCV
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
2
Determine source of air flow restriction.
NG
PREPARATION:
A. Turn off the engine.
B. Disconnect the air inlet line
from CCV.
C. Remove and reinstall fuel tank
cap to relea se system pressure.
D. Restart the engine.
Go to “G. CCV Diagnostics”
(see step 2 on page 22).
EVAP VSV
Fuel Tank
Charcoal
Canister Filter
Disconnect
CCV
Charcoal Canister
Page 13 of 41
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