From the beginning of refueling, the air and vapor inside the fuel tank go via the refueling EVAP vapor cut valve and EVAP/ORVR line to the EVAP canister. The vapor is absorbed by the EVAP canister and the air is released to the atmosphere.
When the refueling has reached the full level of the fuel tank, the refueling EVAP vapor cut valve is closed and refueling is stopped because of auto shut-off. The vapor which was absorbed by the EVAP canister is purged during driving.
WARNING: When conducting Inspections below, be sure to observe the following:
Put a "CAUTION: FLAMMABLE" sign in workshop.
Never smoke while servicing fuel system. Keep open flames and sparks away from work area.
Always to furnish the workshop with a CO2 fire extinguisher.
CAUTION:
Before removing fuel line parts, carry out the following procedures:
Put drained fuel in an explosion-proof container and put lid on securely.
Always replace O-ring when the fuel gauge retainer is removed.
Never kink or twist hose and tube when they are installed.
Never tighten hose and clamps excessively to avoid damaging hoses.
After installation, run engine and check for fuel leakage at connections.
Never attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically.Continued refueling may cause fuel overflow, resulting in fuel spray and possibly a fire.
ON BOARD REFUELING VAPOR RECOVERY (ORVR)
Diagnosis Procedure
1.Inspection START
Check whether the following symptoms are present.
A: Fuel odor from EVAP canister is strong.
B: Cannot refuel/Fuel odor from the fuel filler opening is strong while refueling.
A or B
A >> GO TO 2.
B >> GO TO 7. 2.CHECK EVAP CANISTER
Remove EVAP canister with EVAP canister vent control valve and EVAP control system pressure sensor attached.
Weigh the EVAP canister with EVAP canister vent control valve and EVAP control system pressure sensor attached. The weight should be less than 2.1 kg (4.6 lb).
Is the Inspection result normal?
YES >> GO TO 3.
NO >> GO TO 4. 3.CHECK IF EVAP CANISTER IS SATURATED WITH WATER
Check if water will drain from EVAP canister
Does water drain from the EVAP canister?
YES >> GO TO 4.
NO >> GO TO 6. 4.REPLACE EVAP CANISTER
Replace EVAP canister with a new one.
>> GO TO 5. 5.DETECT MALFUNCTIONING PART
Check the EVAP hose between EVAP canister and vehicle frame for clogging or poor connection.
>> Repair or replace EVAP hose. 6.CHECK REFUELING EVAP VAPOR CUT VALVE
Refer to See: Refueling Vapor Recovery System\Testing and Inspection.
Is the Inspection result normal?
YES >> Inspection END
NO >> Replace refueling EVAP vapor cut valve with fuel tank. 7.CHECK EVAP CANISTER
Remove EVAP canister with EVAP canister vent control valve and EVAP control system pressure sensor attached.
Weigh the EVAP canister with EVAP canister vent control valve and EVAP control system pressure sensor attached. The weight should be less than 2.1 kg (4.6 lb).
Is the Inspection result normal?
YES >> GO TO 8.
NO >> GO TO 9. 8.CHECK IF EVAP CANISTER IS SATURATED WITH WATER
Check if water will drain from EVAP canister.
Does water drain from the EVAP canister?
YES >> GO TO 6.
NO >> GO TO 11. 9.REPLACE EVAP CANISTER
Replace EVAP canister with a new one.
>> GO TO 10. 10.DETECT MALFUNCTIONING PART
Check the EVAP hose between EVAP canister and vehicle frame for clogging or poor connection.
>> Repair or replace EVAP hose. 11.CHECK VENT HOSES AND VENT TUBES
Check hoses and tubes between EVAP canister and refueling control valve for clogging, kinks, looseness and improper connection.
Is the Inspection result normal?
YES >> GO TO 12.
NO >> Repair or replace hoses and tubes. 12.CHECK RECIRCULATION LINE
Check recirculation line for clogging, dents and cracks.
Is the Inspection result normal?
YES >> GO TO 13.
NO >> Replace fuel filler tube. 13.CHECK REFUELING EVAP VAPOR CUT VALVE
Refer to See: Refueling Vapor Recovery System\Testing and Inspection.
Is the Inspection result normal?
YES >> GO TO 14.
NO >> Replace refueling EVAP vapor cut valve with fuel tank. 14.CHECK FUEL FILLER TUBE
Check fuel filler tube and hose connected to the fuel tank for clogging, dents and cracks.
Is the Inspection result normal?
YES >> GO TO 15.
NO >> Replace fuel filler tube. 15.CHECK ONE-WAY FUEL VALVE-I
Check one-way valve for clogging.
Is the Inspection result normal?
YES >> GO TO 16.
NO >> Repair or replace one-way fuel valve with fuel tank. 16.CHECK ONE-WAY FUEL VALVE-II
Check that fuel is drained from the tank.
Remove fuel filler tube and hose.
Check one-way fuel valve for operation as per the following. When a stick is inserted, the valve should open, when removing stick it should close.
Do not drop any material into the tank.
Is the Inspection result normal?
YES >> Inspection END
NO >> Replace fuel filler tube or replace one-way fuel valve with fuel tank.
