P0440 Fixed!
I want to start off saying the thread above is great and has a ton of info to get down and dirty with the evap system.
I had the same code that would come and go. I would clear it and sometimes it would come back in a week...sometimes months later. I was putting it off and putting it off, but finally it was coming back reliably.
After much consideration, I just said to heck with it, and decided to replace nearly the whole system. My reasoning is that this is to still be my daily driver for years to come so I'm really loathe to futz with it every other weekend as plastic part after plastic part may go bad over time. I already dropped the tank once for the sender and it was not a fun job and I *REALLY* don't want to deal with dropping the tank again.
I'm grouping things into 2 sections. The gas tank for one and the charcoal canister/fuel filler tube. I recommend just doing everything for the gas tank at once. The filler tube and charcoal canister can be done anytime after.
Part 1!
Parts for the fuel tank. Starred (*) parts are really not needed or you can use standard hose:
Code:
Check Valve 77390-35010 1 $48.58 <- Often the problem.
Gasket - check valve 77177-33010 1 $10.36 <- Cracks and can leak.
Cut-Off Valve 77380-26010 1 $11.15 <- Cheap but probably never breaks.
Gasket - cut off 77179-26011 1 $2.20 <- Deteriorates. Replace.
Tube, Fuel Suction 77203-35660 1 $94.15 <- You get a new vent sensor with this.
Sending Unit 83320-35620 1 $87.91 <- They go bad. Just replace it.
Fuel Pump Kit (Denso) 950-0100 1 $87.43 <- 250k miles on it. Time to replace.
*Fuel Filler Hose 77213-35360 1 $39.07 <- Check for damage.
*Fuel Pump Cushion 23249-74610 1 $9.24 <- Does not wear much.
*Breather Tube 77394-35010 1 $9.05 <- Use standard fuel hose.
*Hose 77259-35330 1 $9.96 <- Standard hose will work.
*Fuel Pump Tank Seal 77169-60010 1 $12.28 <- Not needed if you get 77203-35660.
So let's do some totals.
Total fuel tank parts I spent: $421.38
Total fuel tank parts I'd recommend: $341.78
This will replace EVERYTHING to do with the blasted fuel tank. There is literally nothing on the tank that isn't replaced at this point.
One thing to note! The Evap Sensor that is connected to the Fuel Suction Tube:
Is $200 from Toyota! BUT BUT BUT! If you buy the ENTIRE fuel suction assembly, you get it as part of the assembly!
So by buying the fuel suction assembly for $94, you get not just the metal structural piece but also:
NEW Evap sensor.
NEW Evap sensor gasket and yellow clip.
NEW electrical connection and gasket for the pump and sender connection.
NEW plastic fuel hoses and red clip.
NEW Fuel Suction Assembly Gasket.
IMHO, totally worth the $94.
I also replaced all the connecting hoses. Make sure you get the correct metric sizes 6mm or 8mm from your favorite store. I don't like using "whatever" fits. Again...I *REALLY* don't want to deal with this for like 15 more years.
If I had to make a prediction, it was the 77177-33010 check valve gasket. It was dried and cracked all over. Everything else I replaced had no visible signs of wear/damage except for the rubber hoses going to the charcoal cannister/fuel filler. The ends had some cracks but the connection is long so I doubt they were leaking. Regardless, they got replaced.
Last note. Tools and materials:
I got some vacuum grease from Amazon and used it on all hose connections. Expensive but it works great. You need this to install the big black check valve and its gasket properly. Use it on the other connections so that if you need to disconnect again for some reason, the hoses come off easily.
Amazon.com: Dow Corning High Vacuum Grease Lubricant 2oz (57g): Industrial & Scientific
Hose clamp pliers and hose pliers. These changed my life. They break hoses free and remove them so easily in super tight spaces. The clamp pliers open the clamp and hold it open for moving it to where you need it on the hose.
GEARWRENCH 3 Pc. Double-X Hose Grip Plier Set - 82107 - - Amazon.com
Drake Off Road 4502 Hose Clamp Pliers Set - 2 Piece - - Amazon.com
PART 2 coming up!
