2001 TOYOTA SEQUOIA fuel cap

A23669
EVAP Purge Flow:
Canister Purge VSV
(ON)
Vacuum Pump (OFF)Air Filter Fuel Tank fuel tank cap
To Intake Manifold
Pump Module
Pressure Sensor0.02 Inch Orifice
Vent Valve (OFF)
ECM
Soak Timer
Refueling Valve
To Atmosphere
DI±462
± DIAGNOSTICSENGINE
656 Author: Date:
2005 SEQUOIA (RM1146U)
Key±off monitor
This monitor checks for EVAP (Evaporative Emission) system leaks and pump module malfunctions. The
monitor starts 5 hours*
after the ignition switch is turned OFF. More than 5 hours are required to allow enough
time for the fuel to cool down to stabilize the Fuel Tank Pressure (FTP), thus making the EVAP system moni-
tor more accurate.
The electric vacuum pump creates negative pressure (vacuum) in the EVAP system and the pressure is
measured. Finally, the ECM monitors for leaks from the EVAP system, and malfunctions in both the pump
module and purge VSV, based on the EVAP pressure.
HINT:
*:If the engine coolant temperature is not below 35C 5 hours after the ignition switch is turned off, the moni-
tor 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.
Purge flow monitor
The purge flow monitor consists of the two monitors. The 1st monitor is always conducted every time and
the 2nd monitor is activated if necessary.

The 1st monitor
While the engine is running and the purge VSV (Vacuum Switching Valve) 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 0.5 kpa (3.75 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.

DI±478
± DIAGNOSTICSENGINE
672 Author: Date:
2005 SEQUOIA (RM1146U)
13 Check fuel tank cap.
CHECK:
(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.
PREPARATION:
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.

A23477SST
Pressure Gauge
Pressure
B06546
± DIAGNOSTICSENGINE
DI±487
681 Author: Date:
2005 SEQUOIA (RM1146U)
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 install it until
a few click sounds are heard.
NEXT Go to step 37.
28 Replace fuel tank cap.
HINT:
When installing the fuel tank cap, tighten it until a few click sounds are heard.
NEXT Go to step 37.
29 Repair EVAP leak part.
(a) Prepare a rubber hose with a 15 to 18.5 mm inside diame-
ter.
(b) Reinstall the fuel tank cap.
(c) Disconnect the atmospheric side hose of the pump mod-
ule.
(d) Connect the rubber tube to the pump module.
(e) Using SST, pinch the rubber tube to close the canister
passage to air.
SST 00002±6872A
(f) Connect a pressure gauge (SST) to the service port
(green cap near the air cleaner box).
(g) Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28
mmHg).
(h) Apply soapy water to the piping and connecting parts of
the EVAP system. Look for areas where bubbles appear.
This indicates leaking points.
(i) Repair or replace leaking point.
HINT:

If the system has leaks, a whistling sound will be heard.

Disconnect the hose between the canister and the fuel
tank from the canister. Close the canister hose connected
to the fuel tank, and conduct an inspection. In this way, the
fuel tank can be excluded as an area suspected of caus-
ing fuel leaks.
NEXT Go to step 36.

DI±490
± DIAGNOSTICSENGINE
684 Author: Date:
2005 SEQUOIA (RM1146U)
(b) Monitor Conditions
(1) Allow the engine to idle for at least 5 minutes.
(2) Turn the ignition switch to OFF and wait for 6 hours (8 or 10.5 hours).
HINT:
Do not start the engine until checking MONITOR STATUS. If the engine is started, the steps described above
must be repeated.
(c) Monitor Status
(1) Connect a hand±held tester to the DLC3.
(2) Turn the ignition switch to ON and turn the tester ON.
(3) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR
STATUS.
(4) Check the Monitor Status displayed on the tester.
HINT:
If INCMP is displayed, the monitor is not completed. Make sure that the preconditions have been met, and
perform the Monitor Conditions again.
2. PURGE FLOW MONITOR CONFIRMATION (P0441)
HINT:
Perform this monitor confirmation after the Key±Off Monitor Confirmation shows COMPL (complete).
(a) Preconditions
The monitor will not run unless:

The vehicle has been driven for 10 minutes or more (in a city area or on a free way)

The ECT is between 4.4C and 35C (40F and 95F)

The IAT is between 4.4C and 35C (40F and 95F)
(b) Monitor Conditions
(1) Release the pressure from the fuel tank by removing and reinstalling the fuel tank cap.
(2) Warm the engine up until the ECT reaches more than 75C (167F).
(3) Increase the engine speed to 3,000 rpm once.
(4) Allow the engine to idle and turn A/C ON for 1 minute.
(c) Monitor Status
(1) Turn the ignition switch to OFF (where ON or the engine is running).
(2) Connect a hand±held tester to the DLC3.
(3) Turn the ignition switch to ON and turn the tester ON.
(4) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR
STATUS.
(5) Check the Monitor Status displayed on the tester.
HINT:
If INCMP is displayed, the monitor is not completed. Make sure that the preconditions have been met, and
perform the Monitor Conditions again.

A23322
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque Camshaft Timing
Oil Control Valve
(Bank 2) Connector
RH Cylinder
Head Cover
Engine
Wire
Clamp
Bracket
Spark Plug Tube
Gasket
Seal
Washer LH Cylinder
Head Cover
RH Intake
Camshaft
(with Timing
Tube)
Semi±circular Plug
Ground Strap
Ground WireEngine Wire
Clamp
x 9
Camshaft
Timing Oil
Control Valve
(Bank 1)
Camshaft Timing
Oil Control Valve
(Bank 2)
Front
Bearing Cap
Spark PlugGasket
Oil
Feed
Pipe

Seal
Washer
Ground Wire
Camshaft Bearing Cap
16 (160, 12)
O±Ring
LH Exhaust
Camshaft
Camshaft
Housing Plug
Semi±circular
Plug
Strainer

O±Ring
Gasket


LH Intake Camshaft
(with Timing Tube)
RH Exhaust
Camshaft
Camshaft
Housing
Plug
Engine Wire
Bracket

LH Cylinder Head GasketLH Cylinder Head and
Exhaust Manifold Assembly
Air±fuel Ratio Sensor
(Bank 1 Sensor 1) Connector
RH Cylinder
Head Gasket
Engine
Wire
7.5 (76, 66 in.´lbf)
7.5 (76, 66 in.´lbf)
Seal
Washerx 9
x 10

Camshaft Timing
Oil Control Valve
(Bank 1) Connector
Air±fuel Ratio Sensor
(Bank 2 Sensor 1)
Connector
Strainer
1st 40 (408, 30)
2nd Turn 90°
3rd
Turn 90° See page EM±60
Front
Bearing Cap
6.0 (600, 53 in.´lbf)
6.0 (600, 53 in.´lbf)
EM±34
± ENGINE MECHANICALCYLINDER HEAD
2613 Author: Date:
2005 SEQUOIA (RM1146U)

A04015
Wire
Clamp
Bracket
A23333
Rear Water Bypass Joint
A23332
Front Water Bypass Joint
A23331
± ENGINE MECHANICALCYLINDER HEAD
EM±71
2650 Author: Date:
2005 SEQUOIA (RM1146U)
(c) Install the gasket to the cylinder head cover.
(d) Install the seal washer to the bolt.
(e) Install the cylinder head cover with the 9 bolts. Uniformly
tighten the bolts in several steps. Install the 2 cylinder
head covers.
Torque: 6.0 N´m (60 kgf´cm, 53 in.´lbf)
(f) Install the wire clamp bracket on the engine wire to the
camshaft bearing cap.
14. INSTALL ENGINE HANGERS
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
15. INSTALL VVT SENSORS (See page SF±77)
16. INSTALL OIL DIPSTICK AND GUIDE FOR ENGINE
17. INSTALL OIL DIPSTICK AND GUIDE FOR A/T
18. INSTALL IGNITION COILS (See page IG±6)
19. INSTALL REAR WATER BYPASS JOINT
(a) Install 2 new gaskets to the cylinder head.
(b) Install the the water bypass joint with the 4 nuts to the cyl-
inder heads. Alternately tighten the nuts.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
20. INSTALL NO.2 AIR SWITCHING VALVES
(See page EC±26)
21. INSTALL AIR PUMP ASSEMBLY (See page EC±26)
22. INSTALL FRONT WATER BYPASS JOINT
Install 2 new gaskets and the water bypass joint with the 4 nuts.
Alternately tighten the nuts.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
23. INSTALL WATER INLET AND INLET HOUSING AS-
SEMBLY (See page CO±8)
24. ASSEMBLE INTAKE MANIFOLDS
(a) Install the 2 delivery pipes and 8 injectors (see page
SF±31).
(b) Install 2 new gaskets and fuel pulsation damper.
(c) Install a new O±ing and fuel pressure regulator with the
2 bolts.
(d) Install the fuel return pipe to the intake manifold with the
3 bolts.
(e) Connect the fuel return hose to the fuel pressure regula-
tor.

EC0JL±03
B17594
Gasket
B06544
Vacuum Gauge
D13872
Hand±Held Tester
DLC3
CAN VIM
± EMISSION CONTROLEVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
EC±9
2717 Author: Date:
2005 SEQUOIA (RM1146U)
INSPECTION
1. INSPECT LINES AND CONNECTIONS
Visually check for loose connections, sharp bends or damage.
2. INSPECT FUEL TANK
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 to normal operating temperature and
stop the engine.
(b) Install a vacuum gauge (EVAP control system test equip-
ment vacuum gauge) into the EVAP service port on the
purge line.
(c) When using a hand±held tester:
Operation of the VSV for EVAP.
(1) Connect a hand±held tester to the Controller Area
Network Vehicle Interface Module (CAN VIM). Then
connect the CAN VIM to the Date Link Connector 3
(DLC3).
(2) Start the engine.
(3) Turn the hand±held tester ON.
(4) Enter the following menus: DIAGNOSIS / EN-
HANCED OBDII/ ACTIVE TEST / EVAP VAV
(ALONE)

B06546
Pressure Gauge
Pressure
B17596
Fuel Tank Cap
Pressure
Gauge
B17662
Fuel Tank CapFuel Tank
Vent Line Hose
± EMISSION CONTROLEVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
EC±11
2719 Author: Date:
2005 SEQUOIA (RM1146U)
(4) Apply pressure (13.5 to 15.5 in.Aq, 0.99 to 1.14
in.Hq) from the EVAP service port.
Pressure:
The gauge should still read over 7.7 to 8.8 in.Aq (0.57
to 0.65 in.Hq) for 2 minutes after the pressure is ap-
plied.
HINT:
If you cannot apply pressure, the hose connecting the VSV,
charcoal canister and fuel tank has slipped off or the VSV is
open.
(5) Check if the pressure decreases when the fuel tank
cap is removed while applying pressure.
HINT:
If the pressure does not decrease when the filler cap is re-
moved, the hose connecting the service port and the fuel tank
may be blocked.
(k) Disconnect the pressure gauge from the EVAP service
port on the purge line.
5. INSPECT FUEL CUTOFF VALVE AND FILL CHECK
VA LV E
(a) Disconnect the vent line hose from the fuel tank.
(b) Connect the pressure gauge to the fuel tank.
(c) Fill the fuel tank with fuel.
(d) Apply pressure of 4 kPa (41 gf/cm
2,0.58 psi) to the vent
port of the fuel tank.
HINT:
It is necessary to check the amount of fuel in the fuel tank. When
the fuel tank is full, the float valve of the fill check valve is closed
and no air can pass through.
(e) Remove the fuel tank cap, and check that the pressure
drops.
If the pressure does not drop, replace the fuel tank assembly.
(f) Reconnect the vent line hose to the fuel tank.