Refueling Vapor Recovery System: Testing and Inspection

On Board Refueling Vapor Recovery (ORVR)

DIAGNOSTIC PROCEDURE




SYMPTOM: Fuel odor from EVAP canister is strong.




SYMPTOM: Cannot refuel/Fuel odor from the fuel filler opening is strong while refueling.

COMPONENT INSPECTION




Refueling control valve
Check refueling control valve as follows:
1. Remove fuel filler cap.
2. Check air continuity between hose ends (A) and (B).
Blow air into the hose end (B). Air should flow freely into the fuel tank.
3. Blow air into hose end (A) and check there is no leakage.
4. Apply pressure to both hose ends (A) and (B) [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. And check there is no leakage.
If NG, replace refueling control valve with fuel tank.




Refueling EVAP vapor cut valve
1. Remove fuel tank. Refer to "FUEL SYSTEM". Drain fuel from the tank as follows:

With Consult
a. Remove fuel feed hose located on the fuel gauge retainer.
b. Connect a spare fuel hose, one side to fuel gauge retainer where the hose was removed and the other side to a fuel container.
c. Drain fuel using "FUEL PUMP RELAY" in "ACTIVE TEST" mode with CONSULT-II.

OR

Without Consult
a. Remove fuel gauge retainer.
b. Drain fuel from the tank using a hand pump into a fuel container.

2. Check refueling EVAP vapor cut valve for being stuck to close as follows.
Blow air into the refueling EVAP vapor cut valve (from hose end (B)), and check that the air flows freely into the tank.
3. Check EVAP vapor cut valve for being stuck to open as following.
a. Connect vacuum pump to hose ends (A) and (B) using a suitable 3-way connector.
b. Remove fuel gauge retainer with fuel gauge unit.
Always replace 0-ring with new one.
c. Put fuel tank upside down.
d. Apply vacuum pressure to both hose ends (A) and (B) [-13.3 kPa (-100 mmHg, -3.94 inHg)] with fuel gauge retainer remaining open and check that the pressure is applicable. If NG, replace refueling EVAP vapor cut valve with fuel tank.




One-way fuel valve
1. Drain fuel from the tank.
Refer to "COMPONENT INSPECTION" of refueling EVAP vapor cut valve.
2. Remove fuel filler tube and hose.
3. Check one-way fuel valve for operation as follows. When pushing with finger, the valve should open; when finger is released, the valve should shut.
Do not drop any material into the tank.
If NG, replace one-way fuel valve with fuel tank.