Diesel Data: Automotive Repair
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Part 2








2GR-FE ENGINE CONTROL: SFI SYSTEM: P0441: Evaporative Emission Control System Incorrect Purge Flow

DTC P0441 - Evaporative Emission Control System Incorrect Purge Flow

(CONTINUED)

22. PERFORM ACTIVE TEST USING TECHSTREAM (ACTIVE THE VACUUM PUMP)
(a) Turn the ignition switch off.




(b) Disconnect the canister pump module connector.
(c) Turn the ignition switch to ON.
(d) Enter the following menus: Powertrain / Engine / Active Test / Activate the Vacuum Pump.
(e) Measure the voltage according to the value(s) in the table below.
Result:





Text in Illustration





B -- CHECK WIRE HARNESS (ECM - CANISTER PUMP MODULE)
A -- Continue to next step.

23. CHECK WIRE HARNESS (CANISTER PUMP MODULE - BODY GROUND)
(a) Disconnect the canister pump module connector.




(b) Measure the resistance according to the value(s) in the table below.
Result:





Text in Illustration





(c) Reconnect the canister pump module connector.
B -- REPAIR OR REPLACE HARNESS OR CONNECTOR
A -- REPLACE CANISTER
24. CHECK WIRE HARNESS (ECM - CANISTER PUMP MODULE)
(a) Disconnect the canister pump module connector.




(b) Disconnect the ECM connector.
(c) Measure the resistance according to the value(s) in the table below.
Result:





Text in Illustration





(d) Reconnect the canister pump module connector.
(e) Reconnect the ECM connector.
B -- REPAIR OR REPLACE HARNESS OR CONNECTOR
A -- REPLACE ECM
25. INSPECT INTAKE AIR SURGE TANK ASSEMBLY (EVAP PURGE PORT)
(a) Disconnect the EVAP hose from the intake air surge tank assembly.
(b) Start the engine.
(c) Use your finger to confirm that the port of the intake air surge tank assembly has suction.
Result:





(d) Reconnect the EVAP hose.
B -- INSPECT INTAKE AIR SURGE TANK ASSEMBLY (EVAP PURGE PORT)
A -- REPLACE EVAP HOSE (INTAKE AIR SURGE TANK ASSEMBLY - PURGE VSV)
26. 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 install it until a few click sounds are heard.

NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
27. 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)
28. LOCATE EVAP LEAK PART
(a) Disconnect the vent hose.





Text in Illustration





(b) Connect the EVAP pressure tester tool to the canister pump module with the adapter.





Text in Illustration





(c) Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28 mmHg).
(d) Apply soapy water to the piping and connecting parts of the EVAP system.
(e) Look for areas where bubbles appear. This indicates the leak point.
(f) Repair or replace the leak point.
HINT: Disconnect the hose between the canister and fuel tank from the canister. Block the charcoal canister assembly 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)
29. REPLACE CANISTER
(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 air filter; and 3) the fuel tank vent hose.





Text in Illustration





NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
30. REPLACE PURGE VSV




(a) Disconnect the connector and the 2 hoses from the purge VSV.

Text in Illustration





(b) Remove the purge VSV.
(c) Install a new purge VSV.
(d) Reconnect the connector and 2 hoses.
NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
31. REPAIR OR REPLACE HARNESS OR CONNECTOR
NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
32. REPLACE EVAP HOSE (INTAKE AIR SURGE TANK ASSEMBLY - PURGE VSV)
NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
33. INSPECT INTAKE AIR SURGE TANK ASSEMBLY (EVAP PURGE PORT)
(a) Check that the EVAP purge port of the intake air surge tank assembly is not clogged. If necessary, replace the intake air surge tank assembly.
NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
34. REPLACE ECM
(a) Replace the ECM Removal.
NEXT -- PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
35. 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 -- Continue to next step.

36. PERFORM EVAP SYSTEM CHECK (AUTO OPERATION)
NOTICE:
- The Evaporative System Check (Automatic Mode) consists of 5 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 fuel tank leak check 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 an Evaporative System Check, keep the fuel temperature below 35°C (95°F).
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
(c) Turn the Techstream on.
(d) Clear the DTCs DTC Check / Clear.
(e) Enter the following menus: Powertrain / Engine / Utility / Evaporative System Check / Automatic Mode.
(f) After the Evaporative System Check is completed, check for pending DTCs by entering the following menus: Powertrain / Engine / Trouble Codes.
HINT: If no pending DTCs are found, the repair has been successfully completed.

NEXT -- COMPLETED

MONITOR DESCRIPTION

The 2 monitors, key-off and purge flow, are used to detect malfunctions relating to DTC P0441. The key-off monitor is initiated by the ECM internal timer, known as the soak timer, 5 hours*1 after the ignition switch is turned off. The purge flow monitor runs while the engine is running.
1. KEY-OFF MONITOR
5 hours*1 after the ignition switch is turned off, the electric leak detection pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure.
HINT: *1: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later.





*2: If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize.





(a) Purge VSV stuck open
In operation C, the leak detection pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The EVAP system pressure is then measured by the ECM using the canister pressure sensor. If the stabilized system pressure is higher than [second 0.02 inch leak pressure standard x 0.2], the ECM interprets this as the purge VSV being stuck open. The ECM illuminates the MIL and sets the DTC (2 trip detection logic).





(b) Purge VSV stuck closed
In operation D, the canister pressure sensor measures the EVAP (Evaporative Emission) system pressure. The pressure measurement for purge VSV monitor begins when the purge VSV is turned on (open) after the EVAP leak check. When the measured pressure indicates an increase of 0.3 kPa (2.25 mmHg) or more, the purge VSV is functioning normally. If the pressure does not increase, the ECM interprets this as the purge VSV being stuck closed. The ECM illuminates the MIL and sets the DTC (2 trip detection logic).





2. PURGE FLOW MONITOR
The purge flow monitor consists of the 2 step monitors. The 1st monitor is conducted every time and the 2nd monitor is activated if necessary.





- The 1st monitor
While the engine is running and the purge VSV is on (open), the ECM monitors the purge flow by measuring the EVAP pressure change. If negative pressure is not created, the ECM begins the 2nd monitor.
- The 2nd monitor
The vent valve is turned on (closed) and the EVAP pressure is then measured. If the variation in the pressure is less than 0.4 kPa (3.0 mmHg), the ECM interprets this as the purge VSV being stuck closed, and illuminates the MIL and sets DTC P0441 (2 trip detection logic).

Atmospheric pressure check:
In order to ensure reliable malfunction detection, the variation between the atmospheric pressures, before and after conduction of the purge flow monitor, is measured by the ECM.

MONITOR STRATEGY





TYPICAL ENABLING CONDITIONS

All





Key-off Monitor





Purge Flow Monitor





TYPICAL MALFUNCTION THRESHOLDS

Purge VSV Stuck Open





Purge VSV Stuck Closed





Purge Flow





CONFIRMATION DRIVING PATTERN





1. Connect the Techstream to the DLC3.
2. Turn the ignition switch to ON and turn the Techstream on [A].
3. Clear the DTCs (even if no DTCs are stored, perform the Clear DTC procedure) DTC Check / Clear.
4. Start the engine and wait 15 minutes or more [B].
5. Enter the following menus: Powertrain / Engine / Utility / All readiness.
6. Input the DTC: P0441.
7. Check the DTC judgment result [C].





NOTICE:
- The Evaporative System Check (Automatic Mode) consists of 5 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 fuel tank leak check unavailable.
- Do not run the engine during this operation.
- 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 fuel temperature below 35°C (95°F).

8. Turn the ignition switch to ON and turn the Techstream on.
9. Clear the DTCs (even if no DTCs are stored, perform the Clear DTC procedure) DTC Check / Clear [D].
10. Enter the following menus: Powertrain / Engine / Utility / Evaporative System Check / Automatic Mode.
11. After the EVAP SYSTEM CHECK is completed, check for All Readiness by entering the following menus: Powertrain / Engine / Utility / All Readiness.
12. Input the DTC: P0441.
13. Check the DTC judgment result [E].





HINT: If the judgment result shows ABNORMAL, the system has a malfunction.

14. If the test result is UNKNOWN, enter the following menus: Powertrain / Engine / Trouble Codes / Pending.
15. Read Pending DTCs.
HINT: If a pending DTC is output, the system is malfunctioning.

16. If the test result is INCOMPLETE or UNKNOWN and no pending DTC is output, perform a universal trip and check for permanent DTCs DTC Check / Clear.
HINT:
- If a permanent DTC is output, the system is malfunctioning.
- If no permanent DTC is output, the system is normal.

MONITOR RESULT

Refer to Checking Monitor Status Mode 6 Data.
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