engine TOYOTA HIGHLANDER 2001 Service Repair Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2001, Model line: HIGHLANDER, Model: TOYOTA HIGHLANDER 2001Pages: 2572, PDF Size: 34.8 MB
Page 1418 of 2572
05-320
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
510 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)Components
Operations
CanisterContains activated charcoal to absorb EVAP (Evaporative Emissions) generated in fuel tank.
Cut-of f valveLocated in fuel tank. Valve floats and closes when fuel tank is 100 % full.
Purge VSV (Vacuum
Switching Valve)Opens or closes line between canister and intake manifold. ECM uses purge VSV to control EVAP purge flow. In order
to discharge EVAP absorbed by canister to intake manifold, ECM opens purge VSV. EVAP discharge volume to intake
manifold controlled by purge VSV duty cycle ratio (current-carrying time). (Open: ON, Close: OFF)
Refueling valve
Controls EVAP pressure from fuel tank to canister. Valve consists of diaphragm, spring and restrictor (diameter: 0.08
inch). When fuel vapor and pressure inside fuel tank increase, valve opens. While EVAP purged, valve closes and re-
strictor prevents large amount of vacuum from affecting pressure in fuel tank. Valve opened while refueling. When valve
open, adding fuel into fuel tank possible.
Roll-over valveLocated in fuel tank. Valve closes by its own weight when vehicle overturns to prevent fuel from spilling out.
Service portUsed for connecting vacuum gauge for inspecting EVAP system.
Soak timerBuilt into ECM. To ensure accurate EVAP monitor, measures 5 hours* after ignition switch turned to OFF. This allows
fuel to cool down, stabilizing Fuel Tank Pressure (FTP). When apprx. 5 hours
* elapsed, ECM activates.
Pump moduleConsists of (a) to (d) below. Pump module cannot be disassembled.
(a) Vent valve
Vents and closes EVAP system. When ECM turns valve ON, EVAP system closed. When, ECM turns valve OFF, EVAP
system vented. Negative pressure (vacuum) created in EVAP system to check for EVAP leaks by closing purge VSV,
turning on vent valve (closed) and operating vacuum pump (refer to fig. 1).
(b) Pressure sensorIndicates pressure as voltages. ECM supplies regulated 5 V to pressure sensor, and uses feedback from sensor to
monitor EVAP system pressure (refer to fig 2).
(c) Vacuum pumpCreates negative pressure (vacuum) in EVAP system for leak check.
(d) 0.02 inch orificeHas opening with 0.02 inch diameter. Vacuum produced through orifice by closing purge VSV, turning off vent valve and
operating vacuum pump, to monitor 0.02 inch leak pressure. 0.02 inch leak pressure indicates small leak of EVAP.
HINT:
*:If the engine coolant temperature is not below 35C after 5 hours after the ignition switch is turned off, the
monitor check starts 2 hours later. If it is still not below 35C 7 hours after the ignition switch is turned off,
the monitor check starts 2.5 hours later.
Page 1420 of 2572
A85256
C17
Pump Module
BJ1 IO1 IM1E7
E5
E7
E5
E5
E7
E5 18
21
28
4
27
34
8VC
PPMP
E2
MPMP
VPMP
PRG
MRELECM
5V
Pressure Sensor
BJ1 IO1 IM1
BJ1 IO1 IM1
BJ1 IO1 IM1 BJ1 IO1 BJ1 IO1
EB1 16 7 13
12 3
17 15 12
14 5 14
18 16 513 4
1S28
S295 5
LG
BJ1 15
J19
J/C
BFBatteryEH
J2
J/C A AFL MAIN
W
W-B W-B
W-B
2
2I1
2F4EFI No. 2
EFI No. 1EFI Relay
2 53
113
IK3 P-L B
2B2D3
52
Y Engine Room J/BB-R
B-R
Vacuum Pump
Vent Valve
4
3
2
1
8
9Y
YY LLP
L
BRBRBR
WW
BR
RVSB
GRY-G BRBR
B-R
G 12
V4
Purge VSV 6 05-322
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
512 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
WIRING DIAGRAM
Page 1421 of 2572
0.02 inch orifice clogged
Pressure sensor low outputP043E
P043FP0441 P0451 P0452 P0453 P0455 P0456 P2419P2401
P2402
0.02 inch orifice high-flow
Pressure sensor stuck
Pressure sensor noise
Gross leak
Small leak
Vacuum pump stuck OFF
Vacuum pump stuck ON
Vent valve stuck closed
Vent valve stuck open (vent) Purge VSV stuck open
Purge VSV stuck closed
Pressure sensor high output
DTCs
Malfunctioning AreasP2420 P0450
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-323
513 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
INSPECTION PROCEDURE
NOTICE:
A hand-held tester is required to conduct the following diagnostic troubleshooting procedure.
HINT:
Using hand-held tester monitor results enables the EVAP (Evaporative Emission) system to be con-
firmed.
Read freeze frame data using a hand-held tester Freeze frame data record the engine condition when
malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle
was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and
other data, from the time the malfunction occurred.
1 CONFIRM DTC
(a) Turn the ignition switch OFF and wait 10 seconds.
(b) Turn the ignition switch ON.
(c) Turn the ignition switch OFF and wait 10 seconds.
(d) Connect the hand-held tester to the DLC3.
(e) Turn the ignition switch ON and press the hand-held tester switch ON.
(f) Enter the following menus: DIAGNOSIS/ ENHANCED OBD II/ DTC INFO/ CURRENT CODES.
(g) Confirm the DTCs and freeze frame data.
If any EVAP system DTCs are set, the malfunctioning area can be determined using the table below.
NOTICE:
If the 0.02 inch reference pressure difference between the first and second checks is greater than
the specification, the DTCs corresponding to the reference pressure (P043E, P043F, P0441, P0455,
P0456, P2401, P2420) will be all stored.
NEXT
Page 1422 of 2572
05-324
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
514 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
2 PERFORM EVAP SYSTEM CHECK(AUTO OPERATION)
NOTICE:
In the EVAP SYSTEM CHECK (AUTO OPERATION), the series of 5 EVAP SYSTEM CHECK steps
is performed automatically. It takes a maximum of approximately 18 minutes.
Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because
the cut-off valve may be closed and making the leak check of the fuel tank unavailable.
Do not run the engine in this step.
When the temperature of the fuel is 35C (95F) or more, a large amount of vapor forms and any
check results become inaccurate. When performing the EVAP SYSTEM CHECK, keep the tem-
perature below 35C
(95F).
(a) Clear DTCs (see page 05-38).
(b) On the hand-held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYS-
TEM CHECK / EVAP SYS CHECK / AUTO OPERATION.
(c) After the EVAP SYSTEM CHECK is completed, check for pending DTCs by selecting the following
menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES.
HINT:
If no pending DTC is displayed, perform the Monitor Confirmation after this repair is completed. After this
confirmation, check for pending DTCs. If no DTC is displayed, the EVAP system is normal.
NEXT
Page 1423 of 2572
G36782
Purge VSV
Vent Valve
Vacuum Pump
EVAP Pressure
Positive
Leak PressureON: Open
NegativeONON
Steps
(Reference)60 Within 15 minutes 10 60ON
First 0.02 inch
2/5 3/5 4/55/5
OFF: Closed
OFF: Vent ON: Closed
EVAP SYSTEM CHECK
sec sec sec
Normal Pressure
10
sec
1/5
Gross Leak
No Leak Small Leak
TimeLeak Pressure
Second 0.02 inch
StandardStandard x 0.2
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-325
515 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
3 PERFORM EVAP SYSTEM CHECK(MANUAL OPERATION)
NOTICE:
In the EVAP SYSTEM CHECK (MANUAL OPERATION), the series of 5 EVAP SYSTEM CHECK
steps is performed manually.
Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because
the cut-off valve may be closed and making the leak check of the fuel tank unavailable.
Do not run the engine in this step.
When the temperature of the fuel is 35C (95F) or more, a large amount of vapor forms and any
check results become inaccurate. When performing the EVAP SYSTEM CHECK, keep the tem-
perature below 35C
(95F).
(a) Clear DTCs (see page 05-38).
(b) On the hand-held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYS-
TEM CHECK / EVAP SYS CHECK / MANUAL OPERATION.
NEXT
Page 1432 of 2572
A85254
Purge VSV
Hose (to canister)
05-334
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
524 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
12 PERFORM ACTIVE TEST(PURGE VSV)
(a) On the hand-held tester, select the following menu items:
DIAGNOSIS / ENHANCED OBD II/ ACTIVE TEST /
EVAP VSV.
(b) Disconnect the hose (connected to the canister) from the
purge VSV.
(c) Start the engine.
(d) On the tester, turn off the purge VSV (EVAP VSV: OFF).
(e) Use your finger to confirm that the purge VSV has no suc-
tion.
(f) Using the tester, turn on the purge VSV (EVAP VSV: ON).
(g) Use your finger to confirm that the purge VSV has suction.
Result:
Test ResultsSuspected Trouble AreasProceed To
No suction when purge VSV turned OFF, and suction applied
when tuned ONPurge VSV normalA
Suction applied when purge VSV turned OFFPurge VSV stuck openB
No suction when purge VSV turned ON
Purge VSV stuck closed
Problems with EVAP hose between purge VSV and throttle
body
C
(h) Reconnect the hose.
B Go to step 14
C Go to step 15
A
Page 1433 of 2572
A85254
Purge VSV
Hose (to canister)
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-335
525 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
13 CHECK FUEL TANK CAP ASSY
(a) Check that the fuel tank cap is correctly installed.
(b) Confirm that the fuel tank cap is tightened until a few click sounds are heard.
HINT:
If an EVAP tester is available, check the fuel tank cap using the tester.
(1) Remove the fuel tank cap and install it onto a fuel tank cap adaptor.
(2) Connect an EVAP tester pump hose to the adaptor, and pressurize to 3.2 to 3.7 kPa (24 to 28
mmHg) using an EVAP tester pump.
(3) Seal the adaptor and wait for 2 minutes.
(4) Check the pressure. If the pressure is 2 kPa (15 mmHg) or more, the fuel tank cap is normal.
(5) Reinstall the fuel tank cap.
Result:
Test ResultsSuspected trouble AreasProceed To
Fuel tank cap correctly installed'A
Fuel tank cap loose
Fuel tank cap improperly installed
Defective fuel tank cap
Fuel tank cap does not meet OEM specifications
B
No fuel tank cap'C
A Go to step 29
B Go to step 27
C Go to step 28
14 INSPECT VACUUM SWITCHING VALVE ASSY NO.1
(a) Turn the ignition switch to OFF.
(b) Disconnect the 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 suc-
tion.
Result:
Test ResultsSuspected Trouble AreasProceed To
No suctionECMA
Suction appliedPurge VSVB
(f) Reconnect the purge VSV connector.
(g) Reconnect the hose.
A Go to step 35
B Go to step 31
Page 1434 of 2572
A85261
Purge VSV
Hose (to throtlle body)
A68357
A
B Purge VSV
05-336
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
526 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
15 CHECK EVAP HOSE(PURGE VSV - THROTTLE BODY)
(a) Disconnect the hose (connected to the throttle body) from
the purge VSV.
(b) Start the engine.
(c) Use your finger to confirm that the hose has suction.
Result:
Test ResultsSuspected Trouble AreasProceed To
Suction appliedEVAP hose between purge VSV and throttle body
normalA
No suction
Throttle body
EVAP hose between purge VSV and throttle
body
B
(d) Reconnect the hose.
B Go to step 26
A
16 NSPECT VACUUM SWITCHING VALVE ASSY NO.1(PURGE VSV)
(a) Remove the purge VSV.
(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:
Test ResultsSuspected Trouble AreasProceed To
Air flowedPurge VSV normalA
No air flowPurge VSVB
(d) Install the purge VSV.
B Go to step 31
A
Page 1440 of 2572
A85258
Wire Harness Side
C17
Canister
05-342
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
532 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
25 CHECK WIRE HARNESS AND CONNECTOR(PUMP MODULE - GROUND)
(a) Disconnect the C17 canister connector.
(b) Turn the ignition switch to OFF.
(c) Check the resistance between terminal 6 of the canister
connector and the body ground.
Result:
Test ResultsSuspected Trouble AreasProceed To
Below 1 WVacuum pumpA
10 kW or moreWire harness between vacuum pump and body
groundB
(d) Reconnect the canister connector.
A Go to step 30
B Go to step 32
26 INSPECT THROTTLE BODY ASSY
(a) Stop the engine.
(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:
Test ResultsSuspected Trouble AreasProceed To
Suction appliedEVAP hose between throttle body and purge VSVA
No suctionThrottle bodyB
(e) Reconnect the EVAP hose.
A Go to step 33
B Go to step 34
27 CORRECTLY REINSTALL OR REPLACE FUEL TANK CAP
HINT:
When reinstalling the fuel tank cap, tighten it until a few click sounds are heard.
When replacing the fuel tank cap, use a fuel tank cap that meets OEM specifications, and tighten it
until a few click sounds are heard.
NEXT Go to step 37
Page 1443 of 2572
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-345
535 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
37 PERFORM EVAP SYSTEM CHECK(AUTO OPERATION)
NOTICE:
In the EVAP SYSTEM CHECK (AUTO OPERATION), the series of 5 EVAP SYSTEM CHECK steps
is performed automatically. It takes a maximum of approximately 18 minutes.
Do not perform the EVAP 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 35C (95F) or more, a large amount of vapor forms and any
check results become inaccurate. When performing an EVAP SYSTEM CHECK, keep the tem-
perature below 35C
(95F).
(a) Clear DTCs (see page 05-38).
(b) On the hand-held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYS-
TEM CHECK / EVAP SYS CHECK / AUTO OPERATION.
(c) After the SYSTEM CHECK is completed, check for pending DTCs by selecting the following menu
items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES.
HINT:
If no pending DTC is found, the repair has been successfully completed.
NEXT
COMPLETED