Fuel Cap Warning Message System Troubleshooting

Engine

Fuel Cap Warning Message System Troubleshooting

Special Tools Required

*Vacuum Pump/Gauge, 0-30 inHg Snap-on YA4000A or equivalent, commercially available
*Vacuum/Pressure Gauge, 0-4 inHg 07JAZ-001000B

1. Fuel fill cap installation check:

-1. Check the fuel fill cap (the cap must say TIGHTEN TO CLICK). It should turn 1/4 turn after it's tight, then it clicks.

Is the correct fuel fill cap installed and properly tightened?
-YES- Go to step 2.
-NO- Replace the fuel fill cap or tighten the cap, then do the repair verification.

2. Fuel fill cap seal and fuel fill pipe matching surface visual check:

-1. Check the fuel fill cap seal (A) and the fuel fill pipe matching 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 Service and Repair, then do the repair verification.
-NO- Go to step 3.

3. Problem verification:

-1. Reinstall and tighten the fuel fill cap.

-2. Clear the DTC with the HDS. How to Troubleshoot the Fuel And Emissions Systems

-3. Start the engine. Hold the engine speed at 3,000 rpm without load (in P or N) until the radiator fan comes on, then let it idle for 1 minute.

-4. Test drive at 45 mph (72 km/h) for 1 minute or more.

Does the fuel fill cap warning message come on?
-YES- The failure is duplicated. Go to step 4.
-NO- Intermittent failure, the system is OK at this time.

4. EVAP canister purge valve operation check:

-1. Turn the ignition switch to LOCK (0).

-2. Disconnect the vacuum hose (A) from the EVAP canister purge valve (B) in the engine compartment, then connect a T-fitting (C), a vacuum gauge, and a vacuum pump/gauge, 0-30 inHg, to the EVAP canister purge valve as shown.






-3. Turn the ignition switch to ON (II).

-4. Apply about 2 kPa (0.6 inHg, 15 mmHg) of vacuum to the hose.

-5. Select EVAP TEST in the INSPECTION MENU, and do the EVAP PCS ON in the SINGLE SOLENOID with the HDS.

Does the vacuum release immediately?
-YES- The EVAP canister purge valve is OK. Check for a blockage in the vacuum hose between the EVAP canister purge valve and the EVAP canister, then do the repair verification.
-NO- Replace the EVAP canister purge valve Service and Repair, then do the repair verification.

Repair verification:

-1. Install the parts in the reverse order of removal.

-2. Turn the ignition switch to ON (II).

-3. Reset the PCM with the HDS. How to Troubleshoot the Fuel And Emissions Systems

-4. Do the PCM idle learn procedure. PCM Idle Learn Procedure

-5. Start the engine. Hold the engine speed at 3,000 rpm without load (in P or N) until the 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.

Does the fuel fill cap warning message come on?
-YES- Go to step 1.
-NO- Troubleshooting is complete.