Operation CHARM: Car repair manuals for everyone.

On-Vehicle Inspection

INSPECTION

1. INSPECT LINES AND CONNECTIONS
Visually check for loose connections, sharp bends or damage.

2. INSPECT FUEL TANK
Visually check for deformation, cracks or fuel leakage.

3. INSPECT FUEL TANK CAP




Visually check if the cap and/or gasket are deformed or damaged.

If necessary, repair or replace the cap.

4. INSPECT EVAP SYSTEM LINE




a. Warm up the engine and stop the engine.
Allow the engine to warm up to normal operating temperature.

b. Install a vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge line.




c. Hand-held tester:
Forced driving of the VSV for the EVAP.
1. Connect a hand-held tester to the DLC3.
2. Start the engine.
3. Push the hand-held tester main switch ON.
4. Use the ACTIVE TEST mode on the hand-held tester to operate the VSV for the EVAP.




d. If you have no hand-held tester:
Forced driving of the VSV for the EVAP
1. Disconnect the VSV connector for the EVAP.
2. Connect the positive (+) and negative (-) leads from the battery to the VSV terminals for the EVAP.
3. Start the engine.




e. Check the vacuum at idle.

Vacuum: Maintain at 0.368 - 19.713 in.Hg (5 - 268 in.Aq) for over 5 seconds

HINT: If the vacuum does not change, you can conclude that the hose connecting the VSV to the service port has come loose or is blocked, or the VSV is malfunctioning.

f. If you have hand-held tester:
Conclude forced driving of the VSV for the EVAP
1. Stop the engine.
2. Disconnect the hand-held tester from the DLC3.

g. If you have no hand-held tester:
Conclude forced driving of the VSV for the EVAP
1. Stop the engine.
2. Disconnect the positive (+) and negative (-) leads from the battery, and from the VSV terminals for the EVAP.
3. Connect the VSV connector for the EVAP.

h. Disconnect the vacuum gauge from the EVAP service port on the purge line.
i. Connect a pressure gauge to the EVAP service port on the purge line.




j. If you have hand-held tester:
Force driving of the VSV for canister closed valve (CCV)
1. Connect a hand-held tester to the DLC3.
2. Turn the ignition switch ON.
3. Push the hand-held tester main switch ON.
4. Use the ACTIVE TEST mode on the hand-held tester to operate the VSV for CCV.

NOTE: Do not start the engine.

HINT: If the check is not completed within 10 minutes, the forced close of VSV for the CCV will be reset.




k. If you have no hand-held tester:
Forced driving of the VSV for the CCV.
1. Disconnect the VSV connector for the CCV.
2. Connect the positive (+) and negative (-) leads from the battery to the VSV terminals for the CCV




l. Check the pressure.
1. Add the pressure (13.5 - 15.5 in.Aq) from the EVAP service port.

Pressure: 2 minutes after the pressure is added, the gauge should be over 7.7 - 8.8 in.Aq.

HINT: If you can't add pressure, you can conclude that the hose connecting the VSV for EVAP-canister-fuel tank has slipped off or the VSV is open.




2. Check if the pressure decreases when the fuel tank cap is removed while adding pressure.

HINT: If the pressure does not decrease when the filler cap is removed, then you can conclude that the hose connecting the service port to the fuel tank is blocked, etc.

m. If you have hand-held tester:
Conclude forced driving of the VSV for the CCV.
1. Turn ignition switch OFF.
2. Disconnect the hand-held tester from the DLC3.

n. If you have no hand-held tester:
Conclude forced driving of the VSV for the CCV.
1. Disconnect the positive (+) and negative (-) leads from the battery, and from the VSV terminals for the CCV.
2. Connect the VSV connector for the CCV.

o. Disconnect the pressure gauge from the EVAP service port on the purge line.

5. CHECK AIR TIGHTNESS IN FUEL TANK AND FILLER PIPE




a. Disconnect the vent line hose from the fuel tank (See procedure in step 8).
b. Apply pressure to fuel tank and make the internal pressure of the fuel tank 4 kPa (41 gf/sq.cm, 0.58 psi).
c. Check that the internal pressure of the fuel tank is maintained for 1 minute.
d. Check the connected portions of each hose and pipe.
e. Check the installed parts on the fuel tank.

If there is no abnormality, replace the fuel tank and filler pipe.

f. Reconnect the vent line hose to the fuel tank

6. INSPECT FUEL CUT OFF VALVE AND FILL CHECK VALVE




a. Disconnect the vent line hose from the fuel tank
b. Apply 4 kPa (41 gf/sq.cm, 0.58 psi) to the vent port of the fuel tank.

HINT: In the condition that the fuel is full, as the float valve of the fill check valve is closed and has no ventilation, it is necessary to check the fuel amount (volume).

c. Remove the fuel tank cap, and check that pressure drops. If pressure does not drop, replace the fuel tank assembly.
d. Reconnect the vent line hose to the fuel tank.

7. CHECK AIR INLET LINE




a. Disconnect the air inlet line hose from the charcoal canister.
b. Check that there is ventilation in the air inlet line.
c. Reconnect the air inlet line hose to the charcoal canister.

8. REMOVE CHARCOAL CANISTER ASSEMBLY




a. Remove the 4 bolts, and disconnect the charcoal canister and bracket assembly from the body
b. Remove the 4 nuts, and disconnect the charcoal canister from the bracket.
c. Disconnect the VSV connector for the CCV.
d. Disconnect the purge line hose and air inlet line hose from the charcoal canister.
e. Disconnect the vent line hose from the charcoal canister.
1. Deeply push the connector inside.
2. Pinch portion A.
3. Pull out the connector.

f. Remove the charcoal canister.

9. INSPECT CHARCOAL CANISTER




a. Visually check the charcoal canister for cracks or damage.




b. Inspect the charcoal canister operation.
1. While holding the purge port closed, blow air (0.39 kPa, 4.0 gf/sq.cm, 0.06 psi) into the vent port, and check that air flows out from the air inlet port.




2. While holding the air inlet port closed, blow air (0.39 kPa, 4.0 gf/sq.cm, 0.06 psi) into the vent port, and check that air flows out from the purge port.




3. While holding the air inlet port closed, apply vacuum (3.43 kpa, 25.7 gf/sq.cm, 1.01 psi) to the vent port, and check that air is sucked in from the purge port.

If operation is not as specified, replace the charcoal canister.




c. Inspect the air tightness.
1. While holding the vent and air inlet ports closed, apply vacuum (3.43 kpa, 25.7 gf/sq.cm, 1.01 psi) to the purge port, and check that the vacuum is maintained for 1 minute.

HINT: In order to maintain air tightness, the checked should be performed with the CCV terminal port held closed by hand. If operation is not as specified, replace the charcoal canister.




d. Inspect the diaphragm.
1. Remove the air hose between ports A and B.
2. While holding the vent, purge and air inlet ports closed, apply vacuum (1.42 kpa, 11 mmHg, 0.42 in.Hg) into port A, and check that air is sucked in from port B.




3. While holding the vent, purge and air inlet ports closed, apply vacuum (1.42 kpa, 11 mmHg, 0.42 in.Hg) into port A, and measure how long it takes for vacuum to drop.

Vacuum drop time: 10 sec. or more

If operation is not as specified, replace the charcoal canister.

4. Reinstall the air hose between ports A and B.

10. INSPECT CHARCOAL CANISTER FILTER
11. INSPECT VSV FOR CANISTER CLOSED VALVE
12. INSPECT VAPOR PRESSURE SENSOR
13. INSPECT VSV FOR EVAP
14. REINSTALL CHARCOAL CANISTER ASSEMBLY