Section 5

Evaporative Systems Diagnosis

Vacuum Check Valve

On-board Recovery Tank Valve Assembly

Valve (Fill Check Valve)

Vapor Pressure
Sensor Tank Pressure Valve

To Manifold Vacuum

Purge Valve
Filtered Air

Canister Closed Valve

Canister

Air Drain Valve Air Inlet Valve

Bypass Valve
Air Valve Assembly

Learning Objectives: 1. Determine the condition of the EVAP system operation based on
engine data and the EVAP pressure tester.
2. Determine the condition of the vapor pressure sensor.
3. Determine EVAP monitor status using Readiness Tests and
CARB modes.

Engine Control Systems II - Course 874

 Section 5
Evaporative System Diagnosis

EVAP System
Service Port
Vapor EVAP (Purge) VSV
Pressure
Sensor

Bypass
VSV
CCV

Fig.5-1
TL874f501

Overview There are a variety of EVAP systems in use with different monitoring
strategies. It is essential that the EVAP system be correctly identified
before beginning diagnosis (the Repair Manual is the best source). The
following information covers the different systems.

Usually, the customer is unaware of an EVAP system problem until the

MIL illuminates. The customer needs to be aware that they must
correctly install the fuel cap after refueling.

Check mode does not work for EVAP codes. Use the Readiness Test
Confirmation procedure.

A common failure is a leak in the system, but restrictions will also set
EVAP related DTCs.

Engine Control Systems II - Course 874 5-1

Section 5

EVAP System Vacuum Check Valve

with ORVR On-board Recovery Tank Valve Assembly
Valve (Fill Check Valve)

Vapor Pressure
Sensor Tank Pressure Valve

To Manifold Vacuum

Purge Valve
Filtered Air

Canister Closed Valve

Canister

Air Drain Valve Air Inlet Valve

Bypass Valve Fig. 5-2
Air Valve Assembly TL874f502

Condition Purge Air Inlet Tank Tank ORVR Air Drain

Port Port Vacuum Pressure Valve
Ball Check Valve
VSV Purge Valve ON OPEN (V) OPEN (V) CLOSED CLOSED CLOSED CLOSED
VSV Purge Valve OFF CLOSED (NV) CLOSED (NV) CLOSED CLOSED CLOSED CLOSED
Pressure in Tank CLOSED CLOSED CLOSED OPEN CLOSED CLOSED
Vacuum in Tank OPEN CLOSED CLOSED CLOSED
Refill CLOSED CLOSED OPEN OPEN

Late Type
EVAP Pressure
in Fuel Tank
Fuel vapor pressure is
vented into the charcoal
canister when vapor
pressure forces the tank
pressure control valve
open.

Fig. 5-3
TL874f503

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 Evaporative System Diagnosis

Late Type
EVAP Vacuum
in Fuel Tank
Vacuum in the tank can
be relieved by allowing
air to enter through the
charcoal canister or fuel
tank cap.

Fig. 5-4
TL874f504

Late Type
EVAP Purge Mode
During purge, vapors are
drawn out of the canister
and burned in the
engine.

Fig. 5-5
TL874f505

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Section 5

Late Type EVAP

ORVR Operation
During refueling, the
differential pressure valve
and air drain valve are
open. Fuel vapors are
absorbed by the charcoal
canister and excess air is
vented to the
atmosphere.

Fig. 5-6
TL874f506

Evaporative Regulations require that the EVAP system be monitored for system
Systems performance and leak detection. Leaks, restrictions, and many
Monitoring components are checked by measuring the pressure of the EVAP system
at various stages.

Early EVAP systems had to detect a 1mm (0.040 in.) hole and greater. It
is often called the early type or non-intrusive system.

Beginning with 2000 model year, a new EVAP monitor system was
implemented to meet the new, mandated standard of detecting a hole
down to .5mm (0.020 in.). This new system is referred to as the Late
Type or Intrusive Type. The intrusive system is being phased in.

In addition, the EVAP monitor has to monitor vapor purge and

component performance. All EVAP monitor DTCs require two trips.

Early-Type The ECM relies on the VP sensor signal to accurately measure pressure
(Non-Intrusive) in the EVAP system and the purge side of the charcoal canister. The
Pressure changes in the pressures being measured are very small, often 15.5
Detection mmHg (0.3 psi) or less. For the VP sensor to measure tank pressure and
canister pressure, a three-way VSV is connected to the VP sensor, fuel
tank and lines, and charcoal canister. When there is no power to the
three-way VSV VP sensor, the VP sensor measures canister purge
pressure. When the ECM turns on the VSV, the VP sensor measures
fuel tank pressure.

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 Evaporative System Diagnosis

Early Type EVAP Components

Vacuum Check Valve

On-board Recovery Valve Vapor Pressure Sensor VSV

(Fill Check Valve)
Tank Valve Assembly
Vapor Pressure
Sensor Pressure Valve

To Manifold Vacuum

Purge Valve

Filtered Air

Canister

Air Drain Valve Air Inlet Valve

Air Valve Assembly

Fig. 5-7
TL874f507

EVAP Pressure Monitoring

The ECM tests for leaks by measuring Tank Pressure
EVAP system pressure in the lines,
charcoal canister, and fuel tank. When
Atmospheric Pressure

the EVAP pressure is higher or lower

than atmospheric pressure, the ECM
concludes that no leaks are present.
EVAP pressure is measured by the VP
sensor. If either the tank or canister
purge side is at atmospheric pressure
under specific conditions, the ECM
determines there is a leak.

20 Minutes

Fig. 5-8
TL874f508

Engine Control Systems II - Course 874 5-5

Section 5

HC Leak A leak can generate multiple DTCs depending on component and

Detection - location. Refer to the Repair Manual for the proper sequence for
P0440, P0441, diagnosing these DTCs.
P0446
The ECM tests for leaks by measuring EVAP system pressure in the
lines, charcoal canister, and fuel tank. When the EVAP pressure is
higher or lower than atmospheric pressure, the ECM concludes that no
leaks are present. EVAP pressure is measured by the VP sensor. If either
the tank or canister purge side is at atmospheric pressure under specific
conditions, the ECM determines there is a leak.

The leak could be a filler cap not properly tightened, a hole in the lines,
charcoal canister, or fuel tank. A visual inspection of the EVAP is
performed for most EVAP diagnostic procedures. Inspection begins with
the filler cap, hoses and tank.

The number of times the leak detection test is performed is determined

by the regulations for that model year and test conditions. The monitor
runs depending on engine temperature and vehicle operating conditions.
If a leak is detected on two consecutive trips (providing the monitor ran
and completed on each trip), the MIL is illuminated and a DTC is stored.
(For details for DTC(s) see P0440, P0441, & P0446)

P0440: If DTC P0440 is present, the leak is on the fuel tank side of the EVAP
Evaporative system. This also includes the lines between the fuel tank and part of
Emission System the canister. When the VP sensor is measuring tank pressure, the ECM
Malfunction is observing changes in pressure and comparing tank pressure to
atmospheric pressure. No difference in pressure indicates a leak. The
ECM may take 20 minutes or more to complete testing the fuel tank side.

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 Evaporative System Diagnosis

Evaporative Monitor P0440

Fig. 5-9
TL874f509

Early Type
EVAP Tank Side
If a leak is suspected,
the shaded areas
should be checked.

Fig. 5-10
TL874f510

Engine Control Systems II - Course 874 5-7

Section 5

P0441: The EVAP monitor is designed to detect:

Vapor Purge
Flow Detection • restricted vapor purge flow when the purge VSV is open

• inappropriate vapor purge flow when the purge VSV is closed

• under normal purge conditions, pressure pulsations generated by

the cycling of the purge VSV are present in the canister and detected
by the VP sensor

Evaporative Monitor P0441

Fig. 5-11
TL874f511

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 Evaporative System Diagnosis

Restricted Vapor During purging under normal conditions, pressure pulsations are
Purge Flow generated by the cycling of the purge VSV and canister pressure drops. If
the VP sensor does NOT detect these pulsations and pressure drop in the
canister, the ECM determines the EVAP system is not working. Possible
causes are, the purge VSV is stuck closed, a restricted purge line, a hole
or disconnected purge line.

Inappropriate Vapor If during starting the canister internal pressure is at atmospheric

Purge Flow pressure, and immediately after starting the canister internal pressure
drops to nearly intake manifold pressure (vacuum), the purge VSV is
open when it should be closed.

Both vapor purge flow conditions set DTC P0441 and the technician must
diagnose the system to find which condition is present.

NOTE DTC P0441 may indicate a leak. If the VP sensor does NOT detect a
pressure drop when the purge control is turned on, a leak may be a
possible cause; for example, a disconnected purge hose.

Early Type
EVAP Vapor Purge
Flow Detection
If a purge flow problem
is suspected, check the
shaded areas. The
purge VSV should
also be checked.

Fig. 5-12
TL874f512

Engine Control Systems II - Course 874 5-9

Section 5

P0446: If DTC P0446 is present, a leak present on the canister purge side may
Three-Way VSV set this code.

NOTE This code can also be set by a malfunctioning three-way VSV. If there is
atmospheric pressure in the canister after the purge VSV is shut off, the
ECM concludes there is a problem with the system.

Evaporative Monitor P0446

Fig. 5-13
TL874f513

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 Evaporative System Diagnosis

Early Type
EVAP Canister
Leak Detection
If a leak is suspected in
the canister, check the
shaded areas.

Fig. 5-14
TL874f514

The three-way VSV is connected to the VP sensor, canister, and fuel tank.
This VSV allows the VP sensor to detect either canister or tank pressure.

There are two modes the ECM can use to determine if the three-way VSV
is malfunctioning. The three-way VSV is judged to be normal if there is
pressure difference between the tank and canister when the three-way
VSV is switched.

If there isn’t any pressure difference between the tank and canister, the
ECM looks for the following conditions:

During purging, if pressure pulsations generated by the purge VSV are

not present in the canister as detected by the VP sensor, the three-way
VSV is judged to be defective.

If there are pressure pulsations detected by the VP sensor present in the

fuel tank, the three-way VSV is judged to be defective.

The logic is that during purging, the VP sensor is supposed to be

monitoring pressure pulsations in the canister. Because the VP sensor
did not see pulsations in the canister but, in the tank during purging, the
ECM concludes the three-way VSV did not switch.

Engine Control Systems II - Course 874 5-11

Section 5

Summary of
Early Type
Evaporative
System DTC(s)

P0440: The fuel tank pressure is atmospheric pressure after the vehicle is
Evaporative driven for 20 minutes. (two trip detection logic)
Emission
Control System
Malfunction

P0441: The pressure in the charcoal canister does not drop during purge
Evaporative control. (two trip detection logic)
Emission
Control System During purge cut-off, the pressure in the charcoal canister is very low
Incorrect Purge compared with atmospheric pressure. (two trip detection logic)
Flow

P0446: When VSV for vapor pressure sensor is OFF, the ECM judges that there
Evaporative is a leak between the vapor pressure sensor and charcoal canister. (two
Emission trip detection logic)
Control System
Vent Control When VSV for vapor pressure sensor is ON, ECM judges that there is a
Malfunction leak between the pressure sensor and fuel tank. (two trip detection
logic)

After the purge cut off operates, the pressure in the charcoal canister is
maintained at atmospheric pressure. (two trip detection logic)

NOTE When diagnosing a P0446 DTC, check the Freeze Frame data. If the
DTC sets at 0 mph, check for a hole in the canister. If a vehicle speed is
recorded, check the 3-way VSV.

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 Evaporative System Diagnosis

Late Type EVAP Components

Vacuum Check Valve

On-board Recovery ORVR Bypass Valve

Valve (Fill Check Valve)
Tank Valve Assembly
Vapor Pressure
Sensor Tank Pressure Valve

To Manifold Vacuum

Purge Valve

Filtered Air

Canister
Closed Valve

Canister

Air Drain Valve Air Inlet Valve

Air Valve Assembly

Fig. 5-15
TL874f515

Late Type The late type, also known as intrusive type, was developed to meet the
(Intrusive) very stringent, mandated standard of detecting a hole 5mm (0.020˝). This
Monitor system uses many of the same components as the early type. Purge,
System vacuum relief, pressure relief, and ORVR operations are identical to the
early type. However, the following items have been changed:

The vapor pressure sensor is connected to the tank and is not switched to
the canister.

The three-way VSV has been replaced with a bypass VSV which connects
the canister and tank during monitor operation.

A closed canister valve (CCV) has been added on the air inlet line allowing
the system to be sealed.

Engine Control Systems II - Course 874 5-13

Section 5

The monitoring for leak detection is different. This system applies a very
small vacuum to the EVAP system. The ECM determines if there is a
problem in the system based on the vapor pressure sensor signal. All
EVAP DTCs require two trips.

The following is a general overview of this monitoring system operation:

• The monitor sequence begins with a cold engine start. The IAT and
ECT sensors must have approximately the same temperature
reading.

• The ECM is constantly monitoring fuel tank pressure. As the

temperature of the fuel increases, pressure slowly rises.

• The ECM will purge the charcoal canister at the appropriate time.
With the bypass VSV closed, pressure will continue to rise in fuel
tank.

Evaporative Monitor

Fig. 5-16
TL874f516

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 Evaporative System Diagnosis

Late Type
EVAP Monitor
Beginning Stages
After a period of driving,
5-20 minutes, the ECM
cycles the purge VSV.

Next, the ECM will close

the CCV and open the
bypass VSV while
continuing to operate the
purge VSV. This will
lower the pressure in the
EVAP system.

When the pressure

reaches a predetermined
point, the purge VSV is
turned off and the valve
is closed. At this point
the ECM will begin to
monitor for a leak by
measuring the rate of
pressure increase.

Fig. 5-17
TL874f517

Engine Control Systems II - Course 874 5-15

Section 5

P0441: At a predetermined point, the ECM closes the CCV and opens the
Purge VSV bypass VSV causing a pressure drop in the entire EVAP system.
Operation
The ECM continues to operate the purge valve until the pressure is
lowered to a specified point at which time the ECM closes the purge
valve.

If the pressure did not drop, or if the drop in pressure decreased beyond
the specified limit, the ECM judges the purge VSV and related
components to be faulty.

P0440 & P0442: The rate of pressure increase, as detected by the vapor pressure signal,
HC Leak indicates if there is a leak and if it is a large or small leak.
Detection
After purge valve operation, the purge VSV is turned off sealing the
vacuum in the system and the ECM begins to monitor the pressure
increase. Some increase in pressure is normal. A very rapid, sharp
increase in pressure indicates a leak in the EVAP system and sets the
DTC P0440.

This monitoring method is also able to distinguish what is called the

small leak detection. A pressure rise just above normal indicates a very
small hole.

CCV Operation
The CCV is commanded
open by the ECM. The
vapor pressure sensor
will measure a rapid
pressure increase.

Fig. 5-18
TL874f518

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 Evaporative System Diagnosis

P0446: This stage checks the CCV and vent (air inlet side) operation. When the
Vent Control, vapor pressure rises to a specified point, the ECM opens the CCV.
CCV Operation Pressure will increase rapidly because of the air allowed into the system.
and Bypass VSV No increase or an increase below specified rate of pressure increase
Operation indicates a restriction on the air inlet side.

In the next stage, the ECM closes the bypass VSV. This action blocks air
entering the tank side of the system. The pressure rise is no longer as
great. If there was no change in pressure, the ECM will conclude the
bypass VSV did not close.

Late Type
(Intrusive)
EVAP Monitor
Sequence

Fig. 5-19
TL874f519

P0450 & P0451: These two DTCs indicate a faulty VP sensor or circuit on Early and Late
VP Sensor type EVAP systems. These DTCs are not set instantly, for the ECM
measures VP sensor signal under a variety of conditions and may require
the EVAP monitor to complete. Both DTCs require two trips.

Engine Control Systems II - Course 874 5-17

Section 5

To set DTC P0450, after starting, the ECM monitors the VP sensor for
10 seconds. If the VP sensor measures over 4.5V or under 0.5V for at
least 7 seconds of the 10 seconds after starting in both the canister and
tank, the VP sensor is judged to have failed.

For DTC P0451, after 10 seconds, the voltage criteria is 4.9V and 0.10V.
If the VP sensor exceeds these specifications for over 7 seconds, the VP
sensor is judged as faulty. Within a 10 seconds period, between 5 to 15
seconds after stopping the vehicle, the tank pressure is monitored. If
the VP sensor output fluctuates beyond the programmed specifications,
the VP sensor is judged to have failed. For example, 3.83V (+5 mmHg)
and 2.77V (-5 mmHg) have occurred more than 7 times within the 10
seconds period.

Vapor Pressure Though there are different styles of vapor pressure sensors, they use
Sensor Circuit the same style circuit.

The Vapor Pressure Sensor (VPS) measures the vapor pressure in the
evaporative emission control system. The vapor pressure sensor may be
located on the fuel tank, near the charcoal canister assembly or in a
remote location.

Atmospheric
Vapor Pressure Pressure

Sensor Operation Silicon Chip

Diaphragm

The pressure inside the

reference chamber
changes with
atmospheric pressure. Reference Chamber
The reference chamber
pressure uses a small
flexible diaphragm
exposed to atmospheric
pressure. This causes
the reference pressure to
increase with an
increase in atmospheric
pressure. Using this
method allows the vapor
pressure reading to be
calibrated with
atmospheric pressure.

The VPS is extremely

sensitive to changes in
pressure.
Fig. 5-20
1.0 psi = 51.7 mmHg
TL874f520

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 Evaporative System Diagnosis

This sensor uses a silicon chip with a calibrated reference pressure on

one side of the chip. The other side of the chip is exposed to vapor
pressure. Changes in vapor pressure cause the chip to flex and vary the
voltage signal to the ECM. The voltage signal out depends on the
difference between atmospheric pressure and vapor pressure. As vapor
pressure increases, the voltage signal increases. This sensor is sensitive
to very small pressure changes (1.0 psi = 51.7 mmHg).

Types of
Vapor Pressure Sensors

Vapor Pressure
Atmospheric Pressure Vapor Pressure

Tank Mounted Single Hose

Atmospheric Pressure

Vapor Pressure
Vapor Pressure Atmospheric Pressure
Fig. 5-21
Type A Type B TL874f521

Vapor Pressure Sensors come in a variety of configurations. When the

VPS is mounted directly on the fuel pump assembly, no hoses are
required. For remote locations, there may be one or two hoses connected
to the VPS. If the VPS uses one hose, the hose is connected to vapor
pressure. In the two hose configuration, one hose is connected to vapor
pressure, the other hose to atmospheric pressure. It is important that
these hoses are connected to the proper port. If they are reversed, DTCs
will set.

Engine Control Systems II - Course 874 5-19

Section 5

VPS
Electrical Circuit
The ECM receives this
voltage signal at the
PTNK terminal. This
sensor receives 5 volts
from the ECM on the VC
line. The ground for the
sensor is through a
ground wire to the ECM
(usually
terminal E2).

The PTNK signal will be

5 volts if the PTNK wire
is disconnected.
Fig. 5-22
TL874f502

VPS Diagnosis Check all hoses for proper connection, restrictions, and leaks. Check
the VC and E2 voltages. Apply the specified pressure and read sensor
voltage output. The vapor pressure sensor is calibrated for the
pressures found in the EVAP system, so apply only the specified amount
to prevent damaging the sensor.

NOTE Check the Freeze Frame data. Typically, when ENGINE RUN TIME is
less than 200 seconds, carefully check the Vapor Pressure Sensor.

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 Evaporative System Diagnosis

P0450 Evaporative Emission Control System Pressure Sensor Malfunction

ENABLING DETECTING TRIP(S) ECM STRATEGY
STRATEGY CONDITION
Up to 10 sec. after engine Vapor Pressure Sensor > -3.5kPa 2
has started (-26 mmHg, -1.0 in. Hg)
for 7 sec. or more
OR
Vapor Pressure Sensor ≥ 2.0kPa
(15 mmHg, 0.6 in. Hg)
for 7 sec. or more

P0451 Evaporative Emission Control System Pressure Sensor Range Performance

ENABLING DETECTING TRIP(S) ECM STRATEGY
STRATEGY CONDITION
Vehicle Speed 0 mph (0 km/h) Vapor Pressure Sensor output 2
Engine Speed Idling changes extremely
VSV for Vapor Pressure
Sensor is ON
10 sec. or more after the Vapor Pressure Sensor > -4.0kPa 2
engine has started (-30 mmHg, -1.2 in. Hg)
for 7 sec. or more
OR
Vapor Pressure Sensor ≥ 2.0kPa
(15 mmHg, 0.6 in. Hg)
for 7 sec. or more

EVAP The common tools for diagnosis are the Diagnostic Tester and Pressure
Diagnostic tool. Procedures will vary with application. The worksheet attached to this
Tools and section will provide you with a general procedure.
Procedures
The nature of the EVAP system makes it difficult to confirm the repair.
Please refer to the Readiness Confirmation Test.

It is recommended that during a visual inspection, do not wiggle hoses or

tighten fittings and caps until the system has been pressurized.

NOTE When the Intrusive EVAP system is pressurized through the service port,
the EVAP system is pressurized EXCEPT for the fresh air intake line
between the CCV and canister. The CCV and intake line must be
pressurized separately to check for a leak.

Engine Control Systems II - Course 874 5-21

Section 5

5-22 TOYOTA Technical Training

 WORKSHEET 5-1
EVAP Leak Test Confirmation - Intrusive Test

(Instructors’Copy)
Vehicle Year/ Prod. Date Engine Transmission

Worksheet Objectives
This worksheet will guide you in testing and confirming if there is a leak in the Intrusive EVAP system. It will
also show you how to isolate the canister side from the tank side.

Tools and Equipment

• Vehicle

• Vehicle Repair Manual, EWD, & NCF

• Diagnostic Tester

• Hand Tools, Fender Covers, Floor Mats, and Shop Towels

• DVOM

• Test leads

Section 1: Setup and Test

1. On a vehicle selected by the instructor, connect the Diagnostic Tester to the vehicle.

2. DIAGNOSTIC TESTER SETUP: Go to setup menu on the tester and select UNIT CONVERSION.

3. Under VAPOR PRESSURE, select ABS for absolute pressure, and mmHg for millimeters of mercury. This is
to match RM specs.

4. Go back to FUNCTION SELECT and select ENHANCED OBD II.

5. Turn the ignition key to ON.

6. Using a test lead, ground the Closed Canister Valve (CCV) at the ECM and listen for a clicking sound at the
CCV.

Did the CCV "click"?

YES
DO NOT REMOVE the test lead.

Engine Control Systems II - Course 874 5-23

Worksheet 5-1

7. Using a test lead, ground the Bypass (Pressure Switching Valve) VSV (TBP) at the ECM and listen for a
clicking sound at Bypass VSV.

Did the Bypass VSV "click"? YES

DO NOT REMOVE the test lead.

8. What will grounding the CCV and Bypass VSV do to these valves and what does it verify?

The CCV closes the air inlet passage. The Bypass VSV opens the bypass passage.

The "click" verifies the valves are switching positions.

9. Connect the + lead of a DVOM to the Vapor Pressure Sensor pin at the ECM, the - lead to ground E2.

10.Start the engine, activate the EVAP (Purge) VSV. Observe the vapor pressure reading and DVOM. Pressure
should drop to approximately 740mmHg or 1.2 volts (this will vary with altitude and condition of system).
Turn OFF or disconnect EVAP (Purge) VSV.

11.Observe the Vapor Pressure Sensor and DVOM. How long should the EVAP system maintain a vacuum?

Approximately 30 seconds without the voltage rapidly increasing.

12.What is the condition of the system?

13.Create a small leak by opening the gas cap, or at another point as directed by the instructor. Observe DT
and DVOM.

14.What happened to the DT Vapor Pressure Sensor reading and DVOM readings? Which reacted faster?

Both showed an increase in pressure, though the DVOM is more sensitive and reacted faster.
15.Is the vacuum test more useful for locating a leak or verifying a leak exists?

Verifying if a leak exists.

16.What DTC(s) are likely to be reported if there is a leak?

P0440, P0442
17.Restore vehicle to normal condition.

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 EVAP Leak Test Confirmation -
Intrusive Test
Name: __________________________________________________________ Date: _________________________

Review this sheet as you are doing the worksheet. Check each category after completing the
worksheet and instructor presentation. Ask the instructor if you have questions. The comments
section is for you to write where to find the information, questions, etc.

I have questions I know I can

Topic Comment

Locate components using the

EWD and RM

Find wire colors, pin numbers using

the EWD and RM

Set the conditions for the test

Determine if the EVAP system is

leaking

Engine Control Systems II - Course 874 5-25

Worksheet 5-1

5-26 TOYOTA Technical Training

 WORKSHEET 5-2
EVAP System Test - Intrusive Type

(Instructors’Copy)
Vehicle Year/ Prod. Date Engine Transmission

Worksheet Objectives
In this worksheet, you will use the Diagnostic Tester and EVAP Pressure Tester (Miller) to test system integrity
and determine the condition of the EVAP system and components. When finished, you will know how to
diagnose the EVAP system and components.

Tools and Equipment

• Repair Manual

• Vehicle EWD

• EVAP Pressure Tester

• Diagnostic Tester

• DVOM

• Hand Tool Set

Note: Fuel Level should be 1/4 to 3/4 of the tank.

SECTION 1: DIAGNOSTIC TESTER SETUP

1. Go to setup menu on the Diagnostic Tester and select UNIT CONVERSION.

2. Under VAPOR PRESSURE, select ABS for absolute pressure, and mmHg for millimeters of mercury. This is
to match RM specs.

3. Go back to FUNCTION SELECT and select ENHANCED OBD II.

SECTION 2: EVAP SYSTEM

1. Setup the Diagnostic Tester as outlined above.

2. With the key on and engine off, record Tank Vapor Pressure reading _______________mmHg. What does
a reading above or below atmospheric pressure (762 mmHg) indicate?

This reading indicates if the tank side is capable of holding pressure.

Note: DO NOT TIGHTEN or REMOVE the FUEL CAP!

Engine Control Systems II - Course 874 5-27

Worksheet 5-2

Test EVAP Purge Line/Check Purge VSV

This procedure tests for purge flow restrictions, and checks the purge VSV and EVAP purge line connections.
This is done to confirm the operation of these components.

1. Connect EVAP System Pressure Pump to EVAP service port.

• Set pump hold switch to CLOSE.
• Set vent switch to CLOSE.

2. Using the Diagnostic Tester, go to ACTIVE TEST, EVAP (Purge) VSV test.

3. Start the engine. With engine warm @ idle, activate EVAP VSV.

4. Pump gauge should read between - 9 mmHg to - 499 mmHg (-5" H2O to -268" H2O) with the needle
fluctuating. Name two causes for the needle not to fluctuate.

The Purge VSV is not cycling and stuck open

The Purge VSV is not cycling and stuck closed

5. What DTC(s) are possible if the Purge VSV does not operate correctly? (HINT: See monitor sequence)

P0441
6. From air cleaner side, temporarily plug the air inlet line. Pressure should decrease by -10mmHg (- 5" H2O)
or more.

7. If pressure did not decrease, list two causes.

There is a leak at the canister side

There is a leak at the tank side

Note: When both gauge valves are in the CLOSE position, the pump
cannot pressurize the system. The gauge measures the pressure in the
EVAP system.

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 EVAP System Test - Intrusive Type

Pressurize System (System Integrity Check)

This test checks for leaks in the canister and fuel tank sides by pressurizing the system. When the system is
pressurized, it allows you to locate the source of a leak. The CCV and Air Inlet Line are checked separately.

Proceduce Resutls
1. Clamp air drain hose with supplied hose pliers. Condition 1. Pump gauge and vapor pressure


above atmospheric pressure. This indicates:

no leak in canister or tank.

2. Locate the Vapor Pressure Sensor. If the sensor
has two hoses connected to it, disconnect the
hose between the air drain and the sensor and 2. Pump pressure gauge zero, vapor pressure
plug the air drain hose. See Figure 1. above atmospheric pressure (above 762
mmHg). This indicates:

a leak on canister side (see Figure 2 Canister Side)
3. Pressurize EVAP system. Turn off the pump and
seal system (see pump directions).
3. Pump pressure gauge is above atmospheric
 pressure (above zero), vapor pressure is at
762 mmHg. This indicates:

4. Note pump pressure reading and Vapor Pressure

Sensor reading. a leak is on the tank side (See Figure 3 Tank Side)

 4. Pump pressure gauge at zero, vapor

pressure is at 762 mmHg. This indicates:
5. Compare your readings to one of the four results
listed in the right column. Your vehicle had result leak (s) is/are on the canister and tank sides or a leak at a
number _________________.
point common to both sides. Go to Tank Leak Detection Step
6. Next, in the right column, list a probable reason or
for diagnosis.
area that can cause each result.

What DTC(s) are likely to set if there is a leak?

P0440, P0442
After completing the steps above proceed to checking the CCV and air inlet line. This must be done because
this section is not pressurized when the pump pressurizes the system through the service port.

Engine Control Systems II - Course 874 5-29

Worksheet 5-2

Check CCV and Air Inlet Line

This test checks for leaks and restrictions between the canister and CCV; tests CCV operation.

1. Disconnect the air inlet line at the canister.

2. Connect pump to line.

3. Go to ACTIVE TEST, turn on the CCV.

4. Pressurize line, turn pump off. Pressure should hold. If not, check line and CCV.

5. Turn off the CCV, pressure should decrease.

6. Reconnect line.

7. What DTC(s) are possible if the CCV fails?

P0446
Check Bypass (Pressure Switching Valve) VSV Operation
This tests the Bypass VSV for operation and restrictions.

1. Disconnect Bypass VSV lines from canister.

2. Connect pump to one Bypass VSV line.

3. Go to ACTIVE TEST BYPASS VSV.

4. Pressurize Bypass VSV, Turn Pump off.

5. Pressure should hold at this point. If not, what needs to be checked?

Bypass VSV and lines

6. Turn Bypass VSV on, pressure should drop. If not, what component should be checked first?

Bypass VSV
7. Reconnect lines.

8. What DTC(s) are possible if the Bypass VSV fails?

P0446

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 EVAP System Test - Intrusive Type

Return Vehicle to Service

1. After repairs, pressurize the EVAP system to be sure the system does not leak.

2. Remove clamp from air drain. Remove the plug and connect the Vapor Pressure Sensor hose.

3. Enable EVAP monitor according to Readiness Test Confirmation procedure.

Vapor pressure sensor with two hoses - preparation for leak testing

1. Disconnect Here

2. Plug Opening Here

Fuel Hose

Figure 1

Engine Control Systems II - Course 874 5-31

Worksheet 5-2

Areas to Check for Leaks

Canister Side

Figure 2

1. Check shaded areas for leaks (soapy water detection).

Tank Side

Figure 3

1. Disconnect the EVAP hose from the charcoal canister side and then pressurize the fuel tank to
30 mmHg (4 kPa/0.58psi).

2. Check that the internal pressure of the tank can hold for 1 minute. Check shaded areas for leaks
(soapy water detection). If it does, check the canister side.

3. With system pressurized, check shaded areas for leaks (soapy water detection). Inspect fuel tank cap for
leaks and if it is OEM.

5-32 TOYOTA Technical Training

 EVAP System Test - Intrusive Type
Name: __________________________________________________________ Date: _________________________

Review this sheet as you are doing the worksheet. Check each category after completing the
worksheet and instructor presentation. Ask the instructor if you have questions. The comments
section is for you to write where to find the information, questions, etc.

I have questions I know I can

Topic Comment

Locate components using the

EWD and RM

Find wire colors, pin numbers using

the EWD and RM

Set the conditions for the test

Determine if the EVAP system is

leaking

Set the conditions for the test and

operate the EVAP pressure tester

Determine if EVAP system purge

operation is normal

Locate the source of the leak and

determine the cause

Visually inspect tank, fuel cap, lines,

canister

Activate purge VSV with Active Test

Test purge VSV and compare to specs.

to determine condition

Test Vapor Pressure Sensor

Engine Control Systems II - Course 874 5-33

Worksheet 5-2

5-34 TOYOTA Technical Training

 WORKSHEET 5-3
EVAP System Test - Non-Intrusive Type

(Instructors’Copy)
Vehicle Year/ Prod. Date Engine Transmission

Worksheet Objectives
In this worksheet, you will use the Diagnostic Tester and EVAP Pressure Tester (Miller) to test system integrity
and determine the condition of the EVAP system and components.

Tools and Equipment

• Repair Manual

• Vehicle EWD

• EVAP Pressure Tester

• Diagnostic Tester

• DVOM

• Hand Tool Set

Note: Fuel Level should be 1/4 to 3/4 of the tank.

SECTION 1: DIAGNOSTIC TESTER SETUP

1. Go to setup menu on the Diagnostic Tester and select UNIT CONVERSION.

2. Under VAPOR PRESSURE, select ABS for absolute pressure, and mmHg for millimeters of mercury. This is
to match RM specs.

3. Go back to FUNCTION SELECT and select ENHANCED OBD II.

SECTION 2: EVAP SYSTEM

The following procedures are designed to test the operation of the EVAP system with a service port.

1. Setup the Diagnostic Tester as outlined above.

2. With the key on and engine off, record Tank Vapor Pressure reading _______________mmHg. What does a
reading above or below atmospheric pressure indicate?

This reading indicates if the tank side is capable of holding pressure.

Note: DO NOT TIGHTEN or REMOVE the FUEL CAP!

Engine Control Systems II - Course 874 5-35

Worksheet 5-3

Test EVAP Purge Line/Check Purge VSV

This procedure tests for purge flow restrictions, and checks the purge VSV and EVAP purge line connections.
This is done to confirm the operation of these components.

1. Connect EVAP System Pressure Pump to EVAP service port

• Set pump hold switch to CLOSE
• Set vent switch to CLOSE

2. Using the Diagnostic Tester, go to ACTIVE TEST, EVAP (Purge) VSV test

3. Start the engine. With engine warm @ idle, activate EVAP VSV

4. Pump gauge should read between - 9 mmHg to - 499 mmHg (-5" H2O to -268" H2O) with the needle
fluctuating. Name two causes for the needle not to fluctuate.

The Purge VSV is not cycling and stuck open

The Purge VSV is not cycling and closed

5. What DTC(s) are possible if the Purge VSV does not operate correctly? (HINT: See monitor sequence)

P0441
6. From air cleaner side, temporarily plug the air inlet line. Pressure should decrease by -10mmHg (- 5" H2O)
or more.

7. If pressure did not decrease, list two causes.

There is a leak at the canister side

There is a leak at the tank side

Note: When both gauge valves are in the CLOSE position, the pump
cannot pressurize the system. The gauge measures the pressure in the
EVAP system.

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 EVAP System Test - Non-Intrusive Type

Pressurize System (System Integrity Check)

This test checks for leaks in the canister and fuel tank sides by pressurizing the system. When the system is
pressurized, it allows you to locate the source of a leak.

Proceduce Resutls
1. Clamp air drain line with supplied hose pliers. Condition 1. Pump gauge and vapor pressure


above atmospheric pressure. This indicates:

No leak in canister or tank.

2. Pressurize EVAP system. Turn off the pump and
seal system (see pump directions).
2. Pump pressure gauge zero, vapor pressure
 above atmospheric pressure (above 762
mmHg). This indicates:
3. Note pump pressure reading and Vapor Pressure
Sensor reading for the fuel tank. Leak on canister side (see Canister Side, Figure 1)
 3. Pump pressure gauge is above atmospheric
pressure (above zero), vapor pressure is at
4. Note pump pressure reading and Vapor Pressure 762 mmHg. This indicates:
Sensor reading.

 Leak is on the tank side (see Tank Side, Figure 2)

5. Compare your readings to one of the four results 4. Pump pressure gauge at zero, vapor
listed in the right column. Your vehicle had result pressure is at 762 mmHg. This indicates:
number _________________.
Multiple leaks on canister and tank sides or leak at a point
6. Next, in the right column, list a probable reason or common to both sides. Use the Canister and Tank Leak
area that can cause each result.
Detection Steps for diagnosis.

What DTC(s) are likely to set if there is a leak?

P0440
Return Vehicle to Service
1. After repairs, pressurize the EVAP system to be sure the system does not leak.

2. Remove clamp from air drain. Remove the plug and connect the Vapor Pressure Sensor hose.

3. Enable EVAP monitor according to Readiness Test Confirmation procedure.

Engine Control Systems II - Course 874 5-37

Worksheet 5-3

Areas to Check for Leaks

Canister Side

Figure 1

1. With the system pressurized, check shaded areas for leaks (soapy water detection).

Tank Side

Figure 2

1. Inpect fuel tank cap for leaks and see if it is OEM.

2. Check shaded areas for leaks (soapy water detection).

5-38 TOYOTA Technical Training

 EVAP System Test - Non-Intrusive Type
Name: __________________________________________________________ Date: _________________________

Review this sheet as you are doing the worksheet. Check each category after completing the
worksheet and instructor presentation. Ask the instructor if you have questions. The comments
section is for you to write where to find the information, questions, etc.

I have questions I know I can

Topic Comment

Locate components using the

EWD and RM

Find wire colors, pin numbers using

the EWD and RM

Set the conditions for the test

Determine if the EVAP system is

leaking

Set the conditions for the test and

operate the EVAP pressure tester

Determine if EVAP system purge

operation is normal

Locate the source of the leak and

determine the cause

Visually inspect tank, fuel cap, lines,

and canister

Activate purge VSV with Active Test

Test purge VSV and compare to specs.

to determine condition

Test Vapor Pressure Sensor

Engine Control Systems II - Course 874 5-39