TOYOTA CAMRY 1999 Service Repair Manual

EC03D±05
B06534
Vapor Pressure Sensor
ConnectorVSV for Vapor Pressure Sensor
ConnectorEVAP Line Hose
Vent Line Hose
Air Inlet Line Hose
Purge Line Hose
Air Drain Hose
39.2 (400, 29)
N´m (kgf´cm, ft´lbf) : Specified torqueCharcoal Canister
Assembly
Charcoal Canister
Vapor Pressure Sensor
Mounting Bolt
± EMISSION CONTROL (5S±FE)EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
EC±5
1403 Author: Date:
EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
COMPONENTS

EC03E±05
B01082B04812B06707
Type A
Type BGasket
Gasket
B06544
Vacuum
Gauge
S05331
EC±6
± EMISSION CONTROL (5S±FE)EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
1404 Author: Date:
INSPECTION
1. INSPECT LINES AND CONNECTORS
Visually check for loose connections, sharp bends or damage.
2. INSPECT FUEL TANK FILLER PIPE
Visually check for deformation, cracks or fuel leakage.
3. INSPECT FUEL TANK CAP
Visually check if the cap and/or gasket are deformed or dam-
aged.
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 tempera-
ture.
(b) Install a vacuum gauge (EVAP control system test equip-
ment vacuum gauge) to the EVAP service port on the
purge line.
(c) TOYOTA Hand±Held Tester:
Forced driving of the VSV for the EVAP.
(1) Connect a TOYOTA hand±held tester to the DLC3.
(2) Start the engine.
(3) Push the TOYOTA hand±held tester main switch
ON.
(4) Use the ACTIVE TEST mode on the TOYOTA
hand±held tester to operate the VSV for the EVAP.

B06548Battery
B06545
B06543
Hose Clipper
Air Drain Hose
± EMISSION CONTROL (5S±FE)EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
EC±7
1405 Author: Date:
(d) If you have no TOYOTA 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) TOYOTA Hand±Held Tester:
Conclude forced driving of the VSV for the EVAP.
(1) Stop the engine.
(2) Disconnect the TOYOTA hand±held tester from the
DLC3.
(g) If you have no TOYOTA 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 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) Check the pressure.
(1) Close off the air drain hose at the marked position
of the canister with a hose clipper or similar instru-
ment.

B06546
Pressure
Gauge
Pressure
B06547
Fuel Tank Cap
B01250
Air
Disconnect
EVAP Line Hose
B01251
Air
Disconnect
Cap
Disconnect
EVAP Line Hose
Purge Line Hose
Purge Port
EC±8
± EMISSION CONTROL (5S±FE)EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
1406 Author: Date:
(2) 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 con-
necting the VSV
canister
fuel tank has slipped off or the
VSV is open.
(3) 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 re-
moved, then you can conclude that the hose connecting the
service port to the fuel tank is blocked, etc.
(k) Disconnect the pressure gauge from the EVAP service
port on the purge line.
5. CHECK AIRTIGHTNESS IN FUEL TANK AND FILLER
PIPE
(a) Disconnect the EVAP line hose from the charcoal canister
side and then pressurize and make the internal pressure
in the fuel tank 4 kPa (41 gf/cm
2, 0.58 psi).
(b) Check that the internal pressure of the fuel tank can be
hold for 1 minute.
(c) Check the connected portions of each hose and pipe.
(d) Check the installed parts on the fuel tank.
If there is no abnormality, replace the fuel tank and filler pipe.
(e) Reconnect the EVAP line hose to the charcoal canister.
6. INSPECT FUEL CUTOFF VALVE AND FILL CHECK
VA LV E
(a) Disconnect the purge line hose and EVAP line hose from
the charcoal canister.
(b) Plug the cap to the air drain hose.
(c) Pressurize 4 kPa (41 gf/cm
2, 0.58 psi) to the purge port
and check that there is ventilation through the EVAP line
hose.

B01252
AirDisconnect
Air Inlet Line Hose
B01253
Pinch
Push
AA
Pinch
B01148
B01149
Air
Purge Port
Vent Port
Air Drain Port
Cap
EVAP
Port
± EMISSION CONTROL (5S±FE)EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
EC±9
1407 Author: Date:
HINT:
In the condition that the fuel fuel is full, as the float value of the
fill check valve is closed and has no ventilation, it is necessary
to check the fuel amount (volume).
(d) Check if there is any struck in the vent line hose and EVAP
line hose.
If there is no stuck in hoses, replace the fuel cutoff valve and fill
check valve.
(e) Reconnect the purge line hose and EVAP line hose to the
charcoal canister.
7. CHECK AIR INLET LINE
(a) Disconnect the air inlet line hose from the charcoal canis-
ter.
(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) Disconnect the VSV connector.
(b) Disconnect the vapor pressure sensor connector.
(c) Disconnect the purge line hose, EVAP line hose and air
inlet line hose from the charcoal canister.
(d) Disconnect the vent line hose from the charcoal canister.
(1) Push the connector deep inside.
(2) Pinch portion A.
(3) Pull out the connector.
(e) Remove the 2 charcoal canister mounting bolts.
(f) Remove the vapor pressure sensor mounting bolt.
(g) Remove the charcoal canister assembly.
9. INSPECT CHARCOAL CANISTER
(a) Visually check the charcoal canister for cracks or dam-
age.
(b) Inspect the charcoal canister operation.
(1) Plug the vent port with a cap.
(2) While holding the purge port closed, blow air (1.76
kPa, 18 gf/cm
2, 0.26 psi) into the EVAP port and
check that air flows from the air drain port.

B01150
Air
Purge Port
EVAP
Port Air Drain PortAir Inlet Port
B01151Vacuum
Purge PortAir Inlet Port
B01152Vacuum
Purge Port
EVAP
Port
Air Inlet Port
EC±10
± EMISSION CONTROL (5S±FE)EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
1408 Author: Date:
(3) While holding the purge port and the air drain port
closed, blow air (1.76 kPa, 18 gf/cm
2, 0.26 psi) into
the EVAP port and check that air does not flow from
the air inlet port.
(4) Apply vacuum (3.43 kPa, 25.7 mmHg, 1.01 in.Hg)
to the purge port, check that the vacuum does not
decrease when the air inlet port is closed, and
check that the vacuum decreases when the air inlet
port is released.
(5) While holding the air inlet port closed, apply vacuum
(3.43 kPa, 25.7 mmHg, 1.01 in.Hg) to the EVAP port
and check that air flows into the purge port.
If operation is not as specified, replace the charcoal canister.
(6) Remove the cap from the vent port.
10. INSPECT VSV FOR EVAP (See page SF±45)
11. INSPECT VSV FOR VAPOR PRESSURE SENSOR
(See page SF±47)
12. INSPECT VAPOR PRESSURE SENSOR
(See page SF±55)
13. REINSTALL CHARCOAL CANISTER ASSEMBLY

EC03F±03
S05556
EGR Valve
Vacuum HoseVacuum Hose
EGR Valve

Gasket

Non±reusable part
Gasket
± EMISSION CONTROL (5S±FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC±11
1409 Author: Date:
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
COMPONENTS

EC03G±04
S05568
Cap
Filter
B06540
Vacuum Gauge
3±Way Connector
A07370
SST
E1
TE1
B06541
HOTHigh Vacuum at 2,500 rpm
Port R
Disconnect
EC±12
± EMISSION CONTROL (5S±FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
1410 Author: Date:
INSPECTION
1. INSPECT EGR SYSTEM
(a) Inspect and clean the filter in the EGR vacuum modulator.
(1) Remove the cap and filter.
(2) Check the filter for contamination or damage.
(3) Using compressed air, clean the filter.
(4) Reinstall the filter and cap.
HINT:
Install the filter with the coarser surface facing the atmospheric
side (outward).
(b) Using a 3±way connector, connect a vacuum gauge to the
hose between the EGR valve and VSV.
(c) Inspect seating of the EGR valve.
Start the engine and check that the engine starts and runs
at idle.
(d) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843±18020
(e) Inspect the VSV operation with the cold engine.
(1) The engine coolant temperature should be below
55°C (131°F).
(2) Check that the vacuum gauge indicates zero at
2,500 rpm.
(f) Inspect the operation of the VSV and EGR vacuum modu-
lator with the hot engine.
(1) Warm up the engine to above 60°C (140°F).
(2) Check that the vacuum gauge indicates low vacu-
um at 2,500 rpm.
(3) Disconnect the vacuum hose port R of the EGR vac-
uum modulator and connect port R directly to the in-
take manifold with another hose.
(4) Check that the vacuum gauge indicates high vacu-
um at 2,500 rpm.

B06539
Disconnect
S05567
Air Engine Stopped
S05566
Engine at
2,500 rpm
Air
± EMISSION CONTROL (5S±FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC±13
1411 Author: Date:
HINT:
As a large amount of exhaust gas enters, the engine will misfire
slightly.
(g) Remove the vacuum gauge, and reconnect the vacuum
hoses to the proper locations.
(h) Inspect the EGR valve.
(1) Apply vacuum directly to the EGR valve with the en-
gine idling.
(2) Check that the engine runs rough or dies.
(3) Reconnect the vacuum hoses to the proper loca-
tions.
HINT:
As exhaust gas is increasingly recirculated, the engine will start
to misfire.
(i) Remove the SST from the DLC1.
SST 09843±18020
2. INSPECT EGR VACUUM MODULATOR
(a) Disconnect the vacuum hoses from ports P, Q and R of
the EGR vacuum modulator.
(b) Block ports P and R with your finger.
(c) Blow air into port Q, and check that the air passes through
to the air filter side freely.
(d) Start the engine, and maintain speed at 2,500 rpm.
(e) Repeat the above test. Check that there is a strong resis-
tance to air flow.
(f) Reconnect the vacuum hoses to the proper locations.

S05559
EC±14
± EMISSION CONTROL (5S±FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
1412 Author: Date:
3. INSPECT EGR VALVE
(a) Remove the EGR valve.
(1) Disconnect the 2 vacuum hoses from the EGR
valve.
(2) Remove the 2 bolts, 2 nuts, EGR valve and 2 gas-
kets.
(b) Check the EGR valve for sticking and heavy carbon de-
posits.
If a problem is found, replace the valve.
(c) Reinstall the EGR valve.
(1) Temporarily 2 new gasket and the EGR valve with
the 2 nuts and 2 bolts.
(2) Tighten the nuts.
Torque: 13.3 N´m (136 kgf´cm, 10 ft´lbf)
(3) Tighten the bolts.
Torque: 10 N´m (102 kgf´cm, 7 ft´lbf)
(4) Connect the 2 vacuum hoses to the EGR valve.
4. INSPECT VSV FOR EGR (See page SF±43)