Page 1425 of 2572
G36784
Purge VSV
Vent Valve
Vacuum Pump
EVAP Pressure
Positive
ON: Open
NegativeONON
Steps
(Reference)
ON
OFF: Closed
OFF: Vent ON: Closed
10
sec
1/5
Time
Vacuum Pump Stuck ON
60
sec
2/5
Leak Pressure First 0.02 inch
Standard
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-327
517 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
5 PERFORM EVAP SYSTEM CHECK(STEP 1/5 TO 2/5)
(a) Check the EVAP pressure in step 1/5 and 2/5.
Result:
DTCs*Test ResultsSuspected Trouble AreasProceed To
'
Virtually no variation in EVAP pressure during step
1/5. Then decreases to 0.02 inch leak pressure
standard*
Not yet determinedA
P2402Small difference between EVAP pressures during
steps 1/5 and 2/5Vacuum pump stuck ONB
*: The DTCs relating to the EVAP system displayed on a hand-held tester when checking.
HINT:
The first 0.02 inch leak pressure standard is the value determined in step 2/5.
B Go to step 23
A
Page 1426 of 2572

G36785
ON
Within 15 minutes
2/5
0.02 inch Orifice High-flow
Vent Valve Stuck closed
OK
0.02 inch Orifice Clogged
60
sec
3/5
4 sec
Vacuum Pump Stuck OFF
ONON
Purge VSV
Vent Valve
Vacuum Pump
EVAP Pressure
Positive
Negative
Steps
(Reference)TimeON: Open
OFF: Closed
OFF: Vent ON: Closed
Leak Pressure First 0.02 inch
Standard
05-328
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
518 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
6 PERFORM EVAP SYSTEM CHECK(STEP 2/5)
HINT:
Make a note of the pressures checked in steps (a) and (b) below.
(a) Check the EVAP pressure 4 seconds after the vacuum pump is activated*.
(b) Check the EVAP pressure again when it has stabilized. This pressure is the 0.02 inch leak pressure
standard.
*: The vacuum pump begins to operate as step 1/5 is proceeded to step 2/5.
Result:
DTCs*Test ResultsSuspected Trouble AreasProceed To
'EVAP pressure in step (b) between -4.85 kPa
and -1.06 kPa (-36.38 mmHg and -7.95 mmHg)Not yet determinedA
P043F and P2401EVAP pressure in step (b) -1.06 kPa (-7.95
mmHg) or more0.02 inch orifice high-flow
Vacuum pump stuck OFFB
P043EEVAP pressure in step (b) below -4.85 kPa
(-36.38 mmHg)0.02 inch orifice cloggedC
P2419EVAP pressure in step (a) more than -1.06 kPa
(-7.95 mmHg)Vent valve stuck closedD
*: The DTCs relating to the EVAP system displayed on a hand-held tester when checking.
B Go to step 11
C Go to step 30
D Go to step 19
A
Page 1427 of 2572
G36786
ON
Within 15 minutes
2/5
Vent Valve Stuck open (vent)
3/5
ONON
Purge VSV
Vent Valve
Vacuum Pump
EVAP Pressure
Positive
Negative
Steps
(Reference)TimeON: Open
OFF: Closed
OFF: Vent ON: Closed
Leak Pressure First 0.02 inch
Standard
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-329
519 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
7 PERFORM EVAP SYSTEM CHECK(STEP 2/5 TO 3/5)
(a) Check the EVAP pressure increase in step 3/5.
Result:
DTCs*Test ResultsSuspected Trouble AreasProceed To
'
EVAP pressure increases by 0.3 kPa (2.25 mmHg)
or more within 10 seconds of proceeding from step
2/5 to step 3/5
Not yet determinedA
P2420No variation in EVAP pressure despite proceeding
from step 2/5 to step 3/5Vent valve stuck open (vent)B
P0451No variation in EVAP pressure during steps 1/5
through 3/5Pressure sensor malfunction stuckC
*: The DTCs relating to the EVAP system displayed on a hand-held tester when checking.
B Go to step 20
C Go to step 30
A
Page 1428 of 2572
G38126
Purge VSV
Vent Valve
Vacuum Pump
EVAP Pressure
Positive
Leak PressureON: Open
NegativeONON
Steps
(Reference)Within 15 minutesON
First 0.02 inch
3/5
OFF: Closed
OFF: Vent ON: Closed
Time Standard
05-330
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
520 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
8 PERFORM EVAP SYSTEM CHECK(STEP 3/5)
(a) Wait until the EVAP pressure change is less than 0.1 kPa (0.75 mmHg) for 30 seconds.
(b) Measure the EVAP pressure and record it.
HINT:
A few minutes are required for the EVAP pressure to become saturated. When there is little fuel in the fuel
tank, it takes up to 15 minutes.
NEXT
Page 1429 of 2572

G36776
ON
Puge VSV Stuck Closed
4/5
ONON
Purge VSV
Vent Valve
Vacuum Pump
EVAP Pressure
Positive
Negative
Steps
(Reference)TimeON: Open
OFF: Closed
OFF: Vent ON: Closed
OK
10
sec
Leak Pressure First 0.02 inch
Standard
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-331
521 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
9 PERFORM EVAP SYSTEM CHECK(STEP 4/5)
(a) Check the EVAP pressure in step 4/5.
DTCs*Test ResultsSuspected Trouble AreasProceed To
'
EVAP pressure increases by 0.3 kPa (2.25 mmHg)
or more within 10 seconds of proceeding from step
3/5 to step 4/5
Not yet determinedA
P0441
EVAP pressure increases by 0.3 kPa (2.25 mmHg)
or more within 10 seconds of proceeding from step
3/5 to step 4/5Problems in EVAP hose between pure VSV and
throttle bodyB
P0441
Variation in EVAP pressure is less than 0.3 kPa
(2.25 mmHg) for 10 seconds, after proceeding from
step 3/5 to step 4/5
Purge VSV stuck closedC
*: The DTCs relating to the EVAP system displayed on a hand-held tester when checking.
B Go to step 15
C Go to step 12
A
Page 1430 of 2572

G36782
Purge VSV
Vent Valve
Vacuum Pump
EVAP Pressure
Positive
ON: Open
NegativeONON
Steps
(Reference)
ON
OFF: Closed
OFF: Vent ON: Closed
Time
60
sec
5/5
Leak Pressure First 0.02 inch
Standard
Gross Leak
Small Leak
No Leak
Leak PressureSecond 0.02 inch
Standard x 0.2
05-332
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
522 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
10 PERFORM EVAP SYSTEM CHECK(STEP 5/5)
(a) Check the EVAP pressure in step 5/5.
(b) Compare the EVAP pressure in step 3/5 and the second 0.02 inch leak pressure standard (step 5/5).
Result:
DTCs*Test ResultsSuspected Trouble AreasProceed To
'EVAP pressure (step 3/5) lower than the second
0.02 inch leak pressure standard (step 5/5)Not yet determined (no leakage from EVAP system)A
P0441 and
P0455EVAP pressure (step 3/5) higher than [second 0.02
inch leak pressure standard (step 5/5) x 0.2]Purge VSV stuck open
EVAP gross leakB
P0456EVAP pressure (step 3/5) higher than second 0.02
inch leak pressure standard (step 5/5)EVAP small leakB
*: The DTCs relating to the EVAP system displayed on a hand-held tester when checking.
A Go to step 36
B Go to step 12
Page 1431 of 2572
G36788
ON
0.02 inch Oriffice High-flow
3/5
ONON
Purge VSV
Vent Valve
Vacuum Pump
EVAP Pressure
Positive
Negative
Steps
(Reference)TimeON: Open
OFF: Closed
OFF: Vent ON: Closed
Leak Pressure First 0.02 inch
Standard
2/5
Vacuum Pump Stuck OFF
Within 15 minutes
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-333
523 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
11 PERFORM EVAP SYSTEM CHECK(STEP 3/5)
(a) Check the EVAP pressure in step 3/5.
Result:
DTCs*Test ResultsSuspected Trouble AreasProceed To
P043F and
P2401EVAP pressure less than [0.02 inch leak pressure
standard x 0.2]0.02 inch orifice high-flowA
P043F and
P2401EVAP pressure more than [0.02 inch leak pressure
standard x 0.2]Vacuum pump stuck OFFB
*: The DTCs relating to the EVAP system displayed on a hand-held tester when checking.
HINT:
The 0.02 inch leak pressure standard is the value determined in step 2/5.
A Go to step 30
B Go to step 23
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