Part 2

2AZ-FXE ENGINE CONTROL SYSTEM: SFI SYSTEM: P1420,P1421: Evaporative Emission Canister Small Leak - Continued

DTC P1420 - Evaporative Emission Canister Small Leak

DTC P1421 - Evaporative Emission Canister Gross Leak

20. CHECK FUEL TANK CAP ASSEMBLY
(a) Check if the fuel cap is tightened until a few "click" sounds are heard.
(b) If you have the EVAP tester, check the fuel cap using the fuel cap adaptor.
(1) Install the fuel cap to the fuel cap adaptor, and connect the hose from the EVAP tester's pump.
(2) Pressurize the fuel cap adaptor to between 24 and 28 mmHg for 45 seconds.
(3) Stop the pump and seal the fuel cap adaptor.
(4) Wait 2 minutes.
(5) Confirm that the pressure is higher than 15 mmHg.
OK:
Higher than 15 mmHg
NG -- REPLACE FUEL TANK CAP
OK -- Continue to next step.
21. LOCATE EVAP LEAK PART (FUEL VAPOR-CONTAINMENT VALVE - FUEL TANK)

(a) Disconnect the vent hose.
(b) Connect the EVAP tester to the vent hose with the adapter.
(c) Connect the Techstream to DLC3.
(d) Turn the power switch on (IG).
(e) Enter the following menus: Powertrain / Engine / Active Test / Activate the Fuel Vapor - Containment Valve.
(f) Turn the fuel vapor-containment valve ON with the tester.
(g) Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28 mmHg).
(h) Apply soapy water to the piping and connecting parts of the EVAP system.
(i) Look for areas where bubbles appear. This indicates the leak point.
(j) 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 -- Continue to next step.
22. REPLACE MALFUNCTIONING PART
NEXT -- PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC OPERATION))
23. CHECK FUEL VAPOR-CONTAINMENT VALVE ASSEMBLY (POWER SOURCE CIRCUIT)

(a) Disconnect the k1 fuel vapor-containment valve connector.
(b) Connect the Techstream to the DLC3.
(c) Turn the power switch on (IG).
(d) Enter the following menus: Powertrain / Engine / Active Test / Activate the Fuel Vapor - Containment Valve.
(e) Turn the fuel vapor-containment valve ON with the tester.
(f) Measure the voltage between terminals 1 and 2 of the k1 connector.
Standard voltage:
10 to 14 V
OK -- REPLACE FUEL VAPOR-CONTAINMENT VALVE
NG -- Continue to next step.
24. CHECK HARNESS OR CONNECTOR (FUEL VAPOR-CONTAINMENT VALVE - EFI NO. 3 FUSE)

(a) Disconnect the k1 fuel vapor-containment valve connector.
(b) Measure the voltage between terminal k1-2 and body ground.
Standard voltage:
10 to 14 V
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
25. CHECK (FUEL VAPOR-CONTAINMENT VALVE ASSEMBLY - HYBRID VEHICLE CONTROL ECU)

(a) Disconnect the A61 hybrid vehicle control ECU connector.
(b) Disconnect the k1 fuel vapor-containment valve connector.
(c) Measure the resistance.
Standard resistance:

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
26. REPLACE HYBRID VEHICLE CONTROL ECU
(a) Replace the hybrid vehicle control ECU Removal.
NEXT -- PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC OPERATION))
27. REPLACE PURGE VSV
NEXT -- PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC OPERATION))
28. REPLACE CANISTER ASSEMBLY
(a) Replace the canister assembly Removal.
NOTICE: When replacing the canister, check the canister pump module interior and related pipes for water, fuel and 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 hose from the canister to the fuel tank.

NEXT -- PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC OPERATION))
29. REPLACE FUEL VAPOR-CONTAINMENT VALVE
NEXT -- PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC OPERATION))
30. REPLACE FUEL TANK CAP
NEXT -- PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC OPERATION))
31. REPAIR OR REPLACE HARNESS OR CONNECTOR
NEXT -- PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC OPERATION))
32. REPAIR OR REPLACE VACUUM HOSE
NEXT -- PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC OPERATION))
33. PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK (MANUAL OPERATION))
HINT: In the manual operation check, the EVAP system can be checked in signal steps. Valve operation and pressure in each step can also be checked.
(a) Clear the DTCs DTC Check / Clear.
(b) Remove the fuel tank cap and reinstall the fuel cap.
(c) Enter the following menus: Powertrain / Engine / Utility / Evaporative System Check / Manual Mode.
NOTICE:
- In Evaporative System Check (Manual Mode), the series of 9 Evaporative System Check steps is performed automatically. It takes a maximum of approximately 18 minutes.
- Do not perform 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 unavailable.
- 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 Evaporative System Check, keep the temperature below 35°C (95°F).

Tester Display

Manual Operation Step

- Timing Chart

NEXT -- Continue to next step.
34. PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK (MANUAL OPERATION STEP 1))
(a) Select step 1 and wait 10 seconds.
NEXT -- Continue to next step.
35. PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK (MANUAL OPERATION STEP 2))
(a) Perform step 2.
(b) Check the EVAP pressure 2 seconds after the leak detection pump is activated*.
*: The leak detection pump begins to operate at the start of step 2.

Result:

C -- REPLACE CANISTER ASSEMBLY
B -- PERFORM ACTIVE TEST USING TECHSTREAM (VACUUM PUMP)
A -- Continue to next step.
36. PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK (MANUAL OPERATION STEP 3))
(a) Perform step 3.
(b) Check the EVAP pressure change in step 3.

Result:

(d) Check the EVAP pressure again when it has stabilized. This pressure is the canister leak pressure standard.
(e) Compare the first reference pressure with the canister leak pressure.

Result:

D -- LOCATE EVAP LEAK PART (PURGE VSV - CANISTER)
C -- CHECK FUEL VAPOR-CONTAINMENT VALVE ASSEMBLY (POWER SOURCE CIRCUIT)
B -- INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION)
A -- Continue to next step.
37. PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK (MANUAL OPERATION STEP 4))
(a) Perform step 4.
(b) Check the EVAP pressure change in step 4.

Result:

B -- CHECK VACUUM HOSE (PURGE VSV - INTAKE MANIFOLD)
A -- Continue to next step.
38. PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK (MANUAL OPERATION STEP 5))
(a) Perform step 5 and wait 60 seconds.
(b) Check the EVAP pressure. This pressure is the second reference pressure standard.
NEXT -- Continue to next step.
39. PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK (MANUAL OPERATION STEP 6))
(a) Perform step 6 and wait 5 seconds.
NEXT -- Continue to next step.
40. PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK (MANUAL OPERATION STEP 7))
(a) Perform step 7.
(b) Check that the tank pressure and EVAP pressure change.
(c) Check the tank pressure again when it has stabilized. This pressure is the fuel tank leak pressure standard.

Result:

B -- CHECK FUEL VAPOR-CONTAINMENT VALVE ASSEMBLY (POWER SOURCE CIRCUIT)
A -- Continue to next step.
41. PERFORM SYSTEM CHECK (EVAPORATIVE SYSTEM CHECK (MANUAL OPERATION STEP 8))
(a) Perform step 8 and wait 60 seconds.
(b) Check the EVAP pressure. This pressure is the third reference pressure standard.
(c) Compare the tank pressure checked in step 8 with the third reference pressure.

Result:

B -- CHECK FUEL TANK CAP ASSEMBLY
A -- Continue to next step.
42. PERFORM CONFIRMATION DRIVING PATTERN
(a) KEY-OFF MONITOR DRIVE PATTERN
(1) Connect the Techstream to the DLC3.
(2) Confirm the following conditions are satisfied:

- The fuel level is less than 90%.
- The altitude is less than 8,000 ft. (2,400 m).
- The vehicle is stopped (the vehicle speed is less than 2 mph).
- The ECT is 4.4 to 35°C (40 to 95°F.)
- The IAT is 4.4 to 35°C (40 to 95°F).
- Drive the vehicle in a city area or on free-way for 10 minutes or more.

(3) Perform the drive pattern:
1. Allow the engine to idle for 5 minutes or more.
2. Turn the power switch off and wait 6 hours.

(4) Check the monitor status with the Techstream.
(b) PURGE FLOW MONITOR DRIVE PATTERN (P0441)
(1) Connect the Techstream to the DLC3.
(2) Confirm that the following conditions are satisfied:

- The Engine Coolant Temperature (ECT) is more than 4.4°C (40°F).
- The Intake Air Temperature (IAT) is more than 4.4°C (40°F).

(3) Perform the drive pattern:
1. Remove and reinstall the fuel cap to release the fuel tank pressure.
2. Warm up the engine until the ECT reaches 75°C (167°F) or more.
3. Drive vehicle in a city area or on free-way for 10 minutes or more.

(4) Check the monitor status with the Techstream.
NEXT -- PERFORM EVAP SYSTEM (EVAPORATIVE SYSTEM CHECK AGAIN (AUTOMATIC OPERATION))