Fuel Cap Warning Message System Troubleshooting
Fuel Cap Warning Message System TroubleshootingSpecial Tools Required
Vacuum pump/gauge, 0 - 30 in.Hg, Snap-on YA4000A or equivalent, commercially available
When the fuel cap warning message does not go off after fuel cap tightened, or the message turned on frequently, do this troubleshooting procedure.
1. Check the fuel fill cap (the cap must say "TIGHTEN TO CLICK"). It should turn 1/4 after it's tight, then it clicks.
Is the correct fuel fill cap installed and properly tightened?
YES - Go to step 2.
NO - Replace or tighten the cap, then go to step 12.
2. Check the fuel fill cap seal (A) and the fuel fill pipe mating surface (B). Verify that the fuel fill cap tether cord (C) is not caught under the cap.
Is the fuel fill cap seal missing or damaged, is the fuel fill pipe damaged, or is the tether cord caught under the cap?
YES - Replace the fuel fill cap or the fuel fill pipe, then go to step 12.
NO - Go to step 3.
3. Reinstall and tighten the fuel fill cap.
4. Clear the DTC with the HDS.
5. Start the engine. Hold the engine speed at 3000 rpm without load (in Park or neutral) until a radiator fan comes on, then let it idle for 1 minute.
6. Test drive at 45 mph (72 km/h) for 1 minute or more.
Is fuel cap warning message comes on?
YES - Go to step 7.
NO - Intermittent failure, the system is OK at this time.
7. Turn the ignition switch OFF.
8. Disconnect the vacuum hose (A) from the EVAP canister purge valve in the engine compartment, and connect the vacuum pump/gauge 0 - 30 in.Hg, to the EVAP canister purge valve as shown.
9. Apply vacuum to the hose about 2 kPa (0.6 in.Hg, 15 mmHg).
10. Turn the ignition switch ON (II).
11. Select EVAP PCS ON in the INSPECTION MENU with the HDS.
Release the vacuum momentary?
YES - Check for blockage the vacuum hose between EVAP canister purge valve and the EVAP canister, then go to step 12.
NO - Replace the EVAP canister purge valve, then go to step 12.
12. Install the parts in the reverse order of removal.
13. Turn the ignition switch ON (II).
14. Reset the ECM/PCM with the HDS.
15. Do the ECM/PCM idle learn procedure.
16. Start the engine. Hold the engine speed without load (in Park or neutral) until a radiator fan comes on, then let it idle for 1 minutes.
17. Test drive at 45 mph (72 km/h) for 1 minute or more.
Is the fuel cap message comes on?
YES - Go to step 1 and recheck.
NO - Troubleshooting is complete.