1996 TOYOTA RAV4 Vacuum

DI−72
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
4 Check operation of the VSV for EGR (See page SF−43).
NG Replace VSV for EGR.
OK
Check for open and short in harness and con-
nector between R/B No.6 and ECM
(See page IN−30).
5 Check EGR vacuum modulator (See page EC−8).
NG Repair or replace.
OK
6 Check manifold absolute pressure sensor (See page DI−21).
NG Repair or replace.
OK
Check and replace ECM
(See page IN−30).

(2) (1)
(5)
S00043
ECM
VSV
for EVAP
Fuel Tank
Charcoal CanisterVSV for Vapor
Pressure SensorVapor Pressure
Sensor
(4)
(3) DI−76
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
DTC P0440 Evaporative Emission Control System
Malfunction
CIRCUIT DESCRIPTION
The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evap-
orative emission control system.
The ECM decides whether there is an abnormality in the evaporative emission control system based on the
vapor pressure sensor signal.
DTC P0440 is recorded by the ECM when evaporative emissions leak from the components within the dotted
line in fig. 1 below, or when the vapor pressure sensor malfunctions.
DTC No.DTC Detecting ConditionTrouble Area
P0440
The fuel tank pressure is atmospheric pressure after the ve-
hicle is driven for 20 min.
(2 trip detection logic)
Vapor pressure sensor
Fuel tank cap incorrectly installed
Fuel tank cap cracked or damaged
Vacuum hose cracked, holed, blocked, damaged or discon-
nected ( (1) or (2) in fig. 1 ) ( (3) in fig. 1 )
Fuel tank cranked, holed or damaged
Charcoal canister cracked, holed or damaged
DI3ZW−01

− DIAGNOSTICSENGINE
DI−79
1996 RAV4 (RM447U)
5 Check the filler neck for damage.
PREPARATION:
Remove the fuel tank cap.
CHECK:
Visually inspect the filler neck for damage.
NG Replace the filler neck.
OK
6 Check the vacuum hoses between vapor pressure sensor and VSV for vapor
pressure sensor, and VSV for vapor pressure sensor and charcoal canister.
CHECK:
(a) Check that the vacuum hose is connected correctly.
(b) Check the vacuum hose for looseness and disconnection.
(c) Check the vacuum hose for cracks, hole and damage.
NG Repair or replace.
OK
7 Check the hose and tube between fuel tank and charcoal canister.
CHECK:
(a) Check for proper connection of the fuel tank and fuel evap pipe (See page SF−1), fuel evap pipe and
fuel tube under the floor, fuel tube under the floor and charcoal canister.
(b) Check the hose and tube for cracks, hole and damage.
NG Repair or replace.
OK
8 Check the charcoal canister for cracks, hole and damage (See page EC−5).
NG Replace charcoal canister.
OK

A00389
ON
E2
(−)VC
(+)
A00409
ON
PTNK (+) E2 (−)
Vacuum
DI−80
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
9 Check voltage between terminals VC and E2 of ECM connector.
PREPARATION:
(a) Remove side trim cover (See page SF−61).
(b) Turn ignition switch ON.
CHECK:
Measure voltage between terminals VC and E2 of ECM con-
nector.
OK:
Voltage: 4.5 − 5.5 V
NG Check and replace ECM (See page IN−30).
OK
10 Check voltage between terminals PTNK and E2 of ECM connector.
PREPARATION:
(a) Remove side trim cover (See page SF−61).
(b) Turn ignition switch ON.
CHECK:
Measure voltage between terminals PTNK and E2 of ECM con-
nector.
(1) Disconnect the vacuum hose from the vapor pres-
sure sensor.
(2) Using the MITYVAC (Hand−Held Vacuum Pump),
apply vacuum (4.0 kPa, 30 mmHg, 1.18 in. Hg) to
the vapor pressure sensor.
NOTICE:
The vacuum applied to the vapor pressure sensor must be
less than 66.7 kPa (500 mmHg).
OK:
(1) Voltage: 2.9 − 3.7 V
(2) Voltage: 0.5 V or less
OK Go to step 12.
NG
11 Check for open and short in harness and connector between vapor pressure
sensor and ECM (See page IN−30).

S00048
Pressure
− DIAGNOSTICSENGINE
DI−81
1996 RAV4 (RM447U)
NG Repair or replace harness or connector.
OK
Replace vapor pressure senor.
12 Check the fuel tank for cracks and damage.
PREPARATION:
(a) Disconnect the vacuum hose from charcoal canister.
(b) Correctly install the fuel tank cap.
(c) Apply a pressure of 5 kPa (0.05 kgf/cm
2, 0.71 psi) to the
fuel tank.
CHECK:
Check whether the pressure is maintained after 1 minute.
OK:
Pressure applied to the fuel tank is maintained.
NG Replace fuel tank.
OK
It is likely that the vehicle user did not properly close the fuel tank cap. Please explain to the cus-
tomer how to properly install the fuel tank cap.

− DIAGNOSTICSENGINE
DI−83
1996 RAV4 (RM447U) DTC No..
DTC Detecting ConditionTrouble Area
P0441
The pressure in the charcoal canister does not drop during
purge control
(2 trip detection logic)
Open or short in VSV circuit for vapor pressure sensor
VSV for vapor pressure sensor
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
Open or short in VSV circuit for EVAP
VSV for EVAP
Vacuum hose cracks, hole, blocked, damaged or discon-
nected ( (1), (4), (5) and (6) in fig. 1 )
Charcoal canister cracks, hole or damaged
During purge cut−off, the pressure in the charcoal canister is
very low compared with atmospheric pressure
(2 trip detection logic)
P0446
When VSV for vapor pressure sensor is OFF, ECM judges that
there is no continuity between vapor pressure sensor and
charcoal canister
(2 trip detection logic)
When VSV for vapor pressure sensor is ON, ECM judges that
there is no continuity between vapor pressure sensor and fuel
tank
(2 trip detection logic)
After the purge cut off operates, the pressure in the charcoal
canister is maintained at atmospheric pressure
(2 trip detection logic)
WIRING DIAGRAM
Refer to Evaporative Emission Control System Malfunction on page DI−76.
INSPECTION PROCEDURE
HINT:
If DTC P0441, P0446 or P0450 is output after DTC P0440, first troubleshoot DTC P0441, P0446 or P0450.
If no malfunction is detected, troubleshoot DTC P0440 next.
TOYOTA hand−held tester
1 Check the VSV connector for EVAP, VSV connector for vapor pressure sensor
and vapor pressure sensor connector for looseness and disconnection.
NG Repair or connect the VSV or sensor connector.
OK
2 Check the vacuum hose between intake manifold and VSV for EVAP,VSV for
EVAP and charcoal canister, charcoal canister and VSV for vapor pressure sen-
sor, and VSV for vapor pressure sensor and vapor pressure sensor.
CHECK:
(a) Check that the vacuum hose is connected correctly.
(b) Check the vacuum hose for looseness and disconnection.
(c) Check the vacuum hose for cracks, hole, damage, and blockage.
NG Repair or replace.

S02467
Suction
No Suction
− DIAGNOSTICSENGINE
DI−85
1996 RAV4 (RM447U)
6 Check the purge flow.
PREPARATION:
(a) Connect the TOYOTA hand−held tester to the DLC3.
(b) Select the ACTIVE TEST mode on the TOYOTA hand−
held tester.
(c) Disconnect from the charcoal canister the vacuum hose
to the VSV for EVAP.
(d) Start the engine.
CHECK:
When the VSV for EVAP is operated by the TOYOTA hand−
held tester, check whether the disconnected hose applies suc-
tion to your finger.
OK:
VSV is ON:
Disconnected hose applies suction to your finger.
VSV is OFF:
Disconnected hose applies no suction to your finger.
OK Go to step 10.
NG
7 Check the vacuum hose between intake manifold and VSV for EVAP, and VSV for
EVAP and charcoal canister.
CHECK:
(a) Check that the vacuum hose is connected correctly.
(b) Check the vacuum hose for looseness and disconnection.
(c) Check the vacuum hose for cracks, hole, damage and blockage.
NG Repair or replace.
OK
8 Check operation of the VSV for EVAP (See page SF−43).
NG Replace VSV.
OK

− DIAGNOSTICSENGINE
DI−87
1996 RAV4 (RM447U)
11 Check the vacuum between charcoal canister and VSV for vapor pressure sen-
sor, and vapor pressure sensor and VSV for vapor pressure sensor.
CHECK:
(a) Check that the vacuum hose is connected correctly.
(b) Check the vacuum hose for looseness and disconnection.
(c) Check the vacuum hose for cracks, hole, damage and blockage.
NG Repair or replace.
OK
12 Check operation of the VSV for vapor pressure sensor (See page SF−47).
NG Replace VSV.
OK
13 Check for open and short in harness and connector between EFI main relay
(Marking: EFI) and VSV for vapor pressure sensor and ECM (See page IN−30).
NG Repair or replace harness or connector.
OK