Part 2

2UZ-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: EVAP System

EVAP System (Continued)

PROCEDURE

1. CONFIRM DTC
(a) Turn the ignition switch OFF and wait for 10 seconds.
(b) Turn the ignition switch ON.
(c) Turn the ignition switch OFF and wait for 10 seconds.
(d) Connect the Techstream to the DLC3.
(e) Turn the ignition switch ON.
(f) Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
(g) Confirm DTCs and freeze frame data.
If any EVAP system DTCs are set, the malfunctioning area can be determined using the table below.
NOTE:
If the 0.02 inch leak criterion difference between the first and second checks is greater than the specification, the DTCs corresponding to the 0.02 inch leak criterion (P043E, P043F, P0441, P0455, P0456, P2401 and P2420) will all be stored.

NEXT -- Continue to next step.
2. PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
NOTICE:
- The Evaporative System Check (Automatic Mode) consists of five steps performed automatically by the Techstream. It takes a maximum of approximately 18 minutes.
- Do not perform the Evaporative System Check when the fuel tank is more than 90 % full because the cut-off valve may be closed, making the leak check of the fuel tank not possible.
- Do not run the engine in this step.
- When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing the Evaporative System Check, keep the temperature below 35°C (95°F).
(a) Clear the DTCs DTC Check / Clear.
(b) Enter the following menus: Powertrain / Engine and ECT / Utility / Evaporative System Check / Automatic Mode.
(c) After the Evaporative System Check is completed, check for pending DTCs by entering the following menus: Powertrain / Engine and ECT / Trouble Codes / Pending.
HINT: If no pending DTC is displayed, perform the CONFIRMATION DRIVING PATTERN. After this confirmation, check for pending DTCs. If no DTC is displayed, the EVAP system is normal.

NEXT -- Continue to next step.
3. PERFORM EVAP SYSTEM CHECK (MANUAL OPERATION)

NOTICE:
- In the Evaporative System Check (Manual Mode), the series of 5 Evaporative System Check steps are performed manually by the Techstream.
- Do not perform the Evaporative System Check when the fuel tank is more than 90 % full because the cut-off valve may be closed, making the leak check of the fuel tank not possible.
- Do not run the engine in this step.
- When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing the Evaporative System Check, keep the temperature below 35°C (95°F).
(a) Clear the DTCs DTC Check / Clear.
(b) Enter the following menus: Powertrain / Engine and ECT / Utility / Evaporative System Check / Manual Mode.
NEXT -- Continue to next step.
4. PERFORM EVAP SYSTEM CHECK (STEP 1/5)

(a) Check the EVAP pressure in step 1/5.
Result:

*: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1.
B -- REPLACE CANISTER ASSEMBLY
A -- Continue to next step.
5. PERFORM EVAP SYSTEM CHECK (STEP 1/5 TO 2/5)

(a) Check the EVAP pressure in step 1/5 and 2/5.
Result:

*: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1.
HINT: The first 0.02 inch leak criterion is the value determined in step 2/5.

B -- PERFORM ACTIVE TEST USING TECHSTREAM (FOR LEAK DETECTION PUMP)
A -- Continue to next step.
6. PERFORM EVAP SYSTEM CHECK (STEP 2/5)

HINT: Make a note of the pressures checked in the steps below.
(a) Check the EVAP pressure 4 seconds after the leak detection pump is activated* [A}.
(b) Check the EVAP pressure again when it has stabilized. This pressure is the 0.02 inch leak criterion [B}.
*: The leak detection pump begins to operate as step 1/5 proceeds to step 2/5.
Result:

*: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1.
D -- PERFORM ACTIVE TEST USING TECHSTREAM (FOR VENT VALVE)
C -- REPLACE CANISTER ASSEMBLY
B -- PERFORM EVAP SYSTEM CHECK (STEP 3/5)
A -- Continue to next step.
7. PERFORM EVAP SYSTEM CHECK (STEP 2/5 TO 3/5)

(a) Check the EVAP pressure in step 3/5.
Result:

*: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1.
C -- REPLACE CANISTER ASSEMBLY
B -- PERFORM ACTIVE TEST USING TECHSTREAM (FOR VENT VALVE)
A -- Continue to next step.
8. PERFORM EVAP SYSTEM CHECK (STEP 3/5)

(a) Wait until the EVAP pressure change is less than 0.1 kPa (0.75 mmHg) for 30 seconds.
(b) Measure the EVAP pressure and record it.
HINT: A few minutes are required for the EVAP pressure to become saturated. When there is little fuel in the fuel tank, it takes up to 12 minutes.

NEXT -- Continue to next step.
9. PERFORM EVAP SYSTEM CHECK (STEP 4/5)

(a) Check the EVAP pressure in step 4/5.
Result:

*: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1.
C -- PERFORM ACTIVE TEST USING TECHSTREAM (PURGE VSV)
B -- CHECK EVAP HOSE (PURGE VSV - INTAKE MANIFOLD)
A -- Continue to next step.
10. PERFORM EVAP SYSTEM CHECK (STEP 5/5)

(a) Check the EVAP pressure in step 5/5.
(b) Compare the EVAP pressure in step 3/5 and the second 0.02 inch leak criterion (step 5/5).
Result:

*: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1.
B -- PERFORM ACTIVE TEST USING TECHSTREAM (PURGE VSV)
A -- REPAIR OR REPLACE PARTS AND COMPONENTS INDICATED BY OUTPUT DTCS
11. PERFORM EVAP SYSTEM CHECK (STEP 3/5)

(a) Check the EVAP pressure in step 3/5.
Result:

*: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1.
HINT: The first 0.02 inch leak criterion is the value determined in step 2/5.

B -- PERFORM ACTIVE TEST USING TECHSTREAM (FOR LEAK DETECTION PUMP)
A -- REPLACE CANISTER ASSEMBLY
12. PERFORM ACTIVE TEST USING TECHSTREAM (PURGE VSV)

(a) Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VSV for EVAP Control.
(b) Disconnect the hose (connected to the canister) from the purge VSV.
(c) Turn the ignition switch ON.
(d) Using the tester, turn the purge VSV OFF (EVAP VSV: OFF).
(e) Use your finger to confirm that the purge VSV has no suction.
(f) Using the tester, turn the purge VSV ON (EVAP VSV: ON).
(g) Use your finger to confirm that the purge VSV has suction.
Result:

C -- CHECK EVAP HOSE (PURGE VSV - INTAKE MANIFOLD)
B -- INSPECT PURGE VSV
A -- Continue to next step.
13. CHECK FUEL CAP
(a) Check that the fuel cap is correctly installed.
(1) Tighten the fuel cap until a few click sounds are heard.
HINT: If an EVAP tester is available, use the tester to check the fuel cap.
(b) Remove the fuel cap and install it onto the fuel cap adaptor.
(c) Connect an EVAP tester hose to the adaptor, and pressurize the cap to 3.2 to 3.7 kPa (24 to 28 mmHg) using an EVAP tester.
(d) Seal the adaptor and wait for 2 minutes.
(e) Check the pressure. If the pressure is 2 kPa (15 mmHg) or more, the fuel cap is normal.
(f) Reinstall the fuel cap.
Result:

C -- REPLACE FUEL CAP
B -- CORRECTLY REINSTALL OR REPLACE FUEL CAP
A -- LOCATE EVAP LEAK
14. INSPECT PURGE VSV

(a) Turn the ignition switch OFF.
(b) Disconnect the V2 purge VSV connector.
(c) Disconnect the hose (connected to the canister) from the purge VSV.
(d) Start the engine.
(e) Use your finger to confirm that the purge VSV has no suction.
Result:

(f) Reconnect the purge VSV connector.
B -- REPLACE PURGE VSV
A -- REPLACE ECM
15. CHECK EVAP HOSE (PURGE VSV - INTAKE MANIFOLD)

(a) Disconnect the hose (connected to the intake manifold) from the purge VSV.
(b) Start the engine.
(c) Use your finger to confirm that the hose has suction.
Result:

B -- INSPECT INTAKE MANIFOLD (EVAP PURGE PORT)
A -- Continue to next step.
16. INSPECT DUTY PURGE VSV

(a) Remove the purge VSV connector.
(b) Apply battery voltage to the terminals of the purge VSV.
(c) Using an air gun, confirm that air flows from port A to port B.
Result:

B -- REPLACE PURGE VSV
A -- Continue to next step.
17. CHECK HARNESS AND CONNECTOR (POWER SOURCE OF PURGE VSV)

(a) Disconnect the V2 purge VSV connector.
(b) Turn the ignition switch ON.
(c) Measure the voltage between terminal 2 of the purge VSV connector and the body ground.
Result:

(d) Reconnect the purge VSV connector.
B -- REPAIR OR REPLACE HARNESS AND CONNECTOR
A -- Continue to next step.
18. CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM)

(a) Disconnect the V2 purge VSV connector.
(b) Disconnect the E5 ECM connector.
(c) Measure the resistance of the wire harness side connectors.
Standard resistance:

(d) Reconnect the ECM connector.
(e) Reconnect the purge VSV connector.
NG -- REPAIR OR REPLACE HARNESS AND CONNECTOR
OK -- REPLACE ECM
19. PERFORM ACTIVE TEST USING TECHSTREAM (FOR VENT VALVE)

(a) Turn the ignition switch ON.
(b) Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VSV for Vent Valve.
(c) Measure the voltage between terminal VPMP of the ECM connector and the body ground when the vent valve is turned ON (close) and OFF (vent) using the tester.
Result:

B -- REPLACE ECM
A -- INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION)
20. PERFORM ACTIVE TEST USING TECHSTREAM (FOR VENT VALVE)

C -- REPLACE ECM
B -- INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION)
A -- Continue to next step.
21. INSPECT CANISTER PUMP MODULE (POWER SOURCE FOR VENT VALVE)

(a) Turn the ignition switch OFF.
(b) Disconnect the L4 canister connector.
(c) Turn the ignition switch ON.
(d) Measure the voltage between terminal 9 of the canister connector and the body ground.
Result:

B -- REPAIR OR REPLACE HARNESS AND CONNECTOR
A -- Continue to next step.
22. INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION)

(a) Turn the ignition switch OFF.
(b) Disconnect the L4 canister connector.
(c) Apply the battery voltage to terminals 9 and 8 of the canister pump module.
(d) Touch the canister pump module to confirm the vent valve operation.
Result:

(e) Reconnect the canister connector.
B -- REPLACE CANISTER ASSEMBLY
A -- REPAIR OR REPLACE HARNESS AND CONNECTOR
23. PERFORM ACTIVE TEST USING TECHSTREAM (FOR LEAK DETECTION PUMP)

(a) Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the Vacuum Pump.
(b) Measure the voltage between MPMP terminal of the ECM connector and the body ground when the leak detection pump is turned ON and OFF using the tester.
Result:

B -- REPLACE ECM
A -- Continue to next step.
24. CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - ECM)

(a) Turn the ignition switch OFF.
(b) Disconnect the L4 canister connector.
(c) Turn the ignition switch ON.
(d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the Vacuum Pump.
(e) Turn the leak detection pump ON.
(f) Measure the voltage between terminal 1 of the canister connector and the body ground.
Result:

(g) Reconnect the canister connector.
B -- REPAIR OR REPLACE HARNESS AND CONNECTOR
A -- Continue to next step.
25. CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - GROUND)

(a) Disconnect the L4 canister connector.
(b) Turn the ignition switch OFF.
(c) Measure the resistance of the wire harness side connectors between terminal 6 of the canister connector and the body ground.
Result:

(d) Reconnect the canister connector.
B -- REPAIR OR REPLACE HARNESS AND CONNECTOR
A -- REPLACE CANISTER ASSEMBLY
26. INSPECT INTAKE MANIFOLD (EVAP PURGE PORT)
(a) Turn the ignition switch OFF.
(b) Disconnect the EVAP hose from the throttle body.
(c) Start the engine.
(d) Use your finger to confirm that the port of the throttle body has suction.
Result:

B -- INSPECT INTAKE MANIFOLD (EVAP PURGE PORT)
A -- REPLACE EVAP HOSE (INTAKE MANIFOLD - PURGE VSV)
27. CORRECTLY REINSTALL OR REPLACE FUEL CAP
HINT:
- When reinstalling the fuel cap, tighten it until a few click sounds are heard.
- When replacing the fuel cap, use a fuel cap that meets OEM specifications, and tighten it until a few click sounds are heard.

NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
28. REPLACE FUEL CAP
HINT: When installing the fuel cap, tighten it until a few click sounds are heard.

NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
29. LOCATE EVAP LEAK
(a) Reinstall the fuel cap.
(b) Disconnect the vent hose.

(d) Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28 mmHg).
(e) Apply soapy water to the piping and connecting parts of the EVAP system.
(f) Look for areas where bubbles appear. This indicates leak point.
(g) Repair or replace the leak point.
HINT: Disconnect the hose between the canister and the fuel tank from the canister. Block the canister side and conduct an inspection. In this way, the fuel tank can be excluded as an area suspected of causing fuel leaks.

NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
30. REPLACE CANISTER ASSEMBLY
(a) Replace the canister assembly.
NOTE:
When replacing the canister, check the canister pump module interior and related pipes for water, fuel or other liquids. If liquids are present, check for disconnections and/or cracks in the following: 1) the pipe from the air inlet port to the canister pump module; 2) the canister filter; and 3) the fuel tank vent hose.

NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
31. REPLACE PURGE VSV
(a) Disconnect the connector and hoses from the purge VSV.
(b) Remove the purge VSV.
(c) Install a new purge VSV.
(d) Reconnect the connector and hose.
NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
32. REPAIR OR REPLACE HARNESS AND CONNECTOR
NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
33. REPLACE EVAP HOSE (INTAKE MANIFOLD - PURGE VSV)
NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
34. INSPECT INTAKE MANIFOLD (EVAP PURGE PORT)
(a) Remove the throttle body Removal.
(b) Check that the EVAP purge port of the intake manifold is not clogged. If necessary, replace the intake manifold.
NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
35. REPLACE ECM
(a) Replace the ECM Removal.
NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
36. REPAIR OR REPLACE PARTS AND COMPONENTS INDICATED BY OUTPUT DTCS
(a) Repair the malfunctioning areas indicated by the DTCs that had been confirmed when the vehicle was brought in.
NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
37. PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
NOTICE:
- The Evaporative System Check (Automatic Mode) consists of five steps performed automatically by the Techstream. It takes a maximum of approximately 15 minutes.
- Do not perform the Evaporative System Check when the fuel tank is more than 90 % full because the cut-off valve may be closed, making the leak check of the fuel tank not possible.
- Do not run the engine in this step.
- When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing an Evaporative System Check, keep the temperature below 35°C (95°F).
(a) Clear the DTCs DTC Check / Clear.
(b) Enter the following menus: Powertrain / Engine and ECT / Utility / Evaporative System Check / Automatic Mode.
(c) After the System Check is completed, check for pending DTCs by entering the following menus: Powertrain / Engine and ECT / Trouble Codes / Pending.
HINT: If no pending DTC is found, the repair has been successfully completed.

NEXT -- COMPLETED

CONFIRMATION DRIVING PATTERN
HINT: After a repair, check Monitor Status by performing the key-off monitor confirmation and purge flow monitor confirmation described below.

1. Key-off monitor confirmation
(a) Preconditions
The monitor will not run unless:
- The vehicle has been driven for 10 minutes or more (in a city area or on a freeway)
- The fuel tank is less than 90 % full
- The altitude is less than 8000 ft (2400 m)
- The Engine Coolant Temperature (ECT) is between 4.4 to 35°C (40 to 95°F)
- The Intake Air Temperature (IAT) is between 4.4 to 35°C (40 to 95°F)
- The vehicle remains stationary (the vehicle speed is 0 km/h (0 mph))

(b) Monitor Conditions
1 Allow the engine to idle for at least 5 minutes.
2 Turn the ignition switch OFF and wait for 6 hours (8 or 10.5 hours).
HINT: Do not Start the engine until checking Monitor Status. If the engine is started, the steps described above must be repeated.

(c) Monitor Status
1 Connect the Techstream to the DLC3.
2 Turn the ignition switch ON and turn the tester ON.
3 Enter the following menus: Powertrain / Engine and ECT / Monitor / Evaporative System.
4 Check the Monitor Status displayed on the tester.
HINT: If Incomplete is displayed, the monitor is not completed. Make sure that the preconditions have been met, and perform the Monitor Conditions again.

2. Purge flow monitor confirmation (P0441)
HINT: Perform this monitor confirmation after the key-off monitor confirmation shows Complete.

(a) Preconditions
The monitor will not run unless:
- The vehicle has been driven for 10 minutes or more (in a city area or on a freeway)
- The ECT is between 4.4 to 35°C (40 to 95°F)
- The IAT is between 4.4 to 35°C (40 to 95°F)

(b) Monitor Conditions
1 Release the pressure from the fuel tank by removing and reinstalling the fuel cap.
2 Warm the engine up until the ECT reaches more than 75°C (167°F).
3 Increase the engine speed to 3000 rpm once.
4 Allow the engine to idle and turn the A/C ON for 1 minute.

(c) Monitor Status
1 Turn the ignition switch OFF (where ON or the engine is running).
2 Connect the Techstream to the DLC3.
3 Turn the ignition switch ON and turn the tester ON.
4 Enter the following menus: Powertrain / Engine and ECT / Monitor.
5 Check the Monitor Status displayed on the tester.
HINT: If Incomplete is displayed, the monitor is not completed. Make sure that the preconditions have been met, and perform the "Monitor Conditions" procedures again.

MONITOR RESULT

Refer to CHECKING MONITOR STATUS Mode 6 Data.