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Old 05-14-2019, 05:32 PM #1
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UPDATE SOLVED: Infamous Cel, even with new Dealer Gas Cap

My Gfís 2002 4Runner has the check engine light with code P0442.
This is not the first time. I have since replaced the Purge Valve (Denso), a few cracked Vacuum hoses, and the Fuel Cap (Duralast, then Toyota Dealer.

2nd. Time the code went on I checked Purge valve which is working fine.
Change the Autozone Gas cap to Toyota Dealer Cap. Light came on again.

3rd. Time Cel. Took me awhile to do a full emissions Smoke Test but I took it to my friends shop and we lifted on the lift. I removed the spare tire to check the full system with charcoal canister in the rear.
Could not find any leaks in the lines or Canister.
But when we took the 4Runner down from the lift, we noticed all the smoke coming from gas cap door. Bad Gas Cap.

The leaky Gas Cap was only 3 months old from Toyota Dealer, Still Warrantied.
Dealer Changed owners since but honored the warranty and gave me a new gas cap which looked the same as the old one.

Cel went on again and Iím assuming itís the gas cap again.
The O-ring on the Dealer Cap is not a solid Rubber Ring, it has a groove in it facing outwards.

Is there any other aftermarket caps that you guys have had success with?
Did Dealer go cheap on their products and change the original part design?

Any tips would be greatly appreciated
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Last edited by Hollywood1; 12-23-2019 at 02:46 PM.
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Old 05-14-2019, 08:13 PM #2
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Well you've made it pretty far down the FSM P0442/P0440 (same) list of possible culprits:


1) Hose or tube cracked, holed, damaged or loose seal ((3) in Fig. 1)
2) Fuel tank cap incorrectly installed
3) Fuel tank cap cracked or damaged
4) Vacuum hose cracked, holed, blocked, damaged or disconnected ((1) or (2) in Fig. 1)
5) Fuel tank cracked, holed or damaged
6) Charcoal canister cracked, holed or damaged
7) Open or short in vapor pressure sensor circuit
8) Vapor pressure sensor
9) ECM

Luck.
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Old 05-14-2019, 08:28 PM #3
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Thanks for the list.
Iíll have to see if I can have my buddy do another smoke test and get a closer look at for sure if itís the gas cap and not the hose going into the tank.
Gf is getting frustrated at having to drive with the CEL on. Hopefully I can figure it out soon!
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Old 05-14-2019, 08:32 PM #4
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Quote:
Originally Posted by Hollywood1 View Post
But when we took the 4Runner down from the lift, we noticed all the smoke coming from gas cap door. Bad Gas Cap.
You seem to have done all the correct diagnostics, particularly the smoke test, which should identify any leaks.

But reading your words above, I wonder if you made a small leap by connecting smoke coming from the gas cap door to the gas cap itself. Is it possible that the fuel filler tube is cracked somewhere, or a similar defect exists? I'd check it again with the smoke machine, with the gas cap installed, and confirm that the smoke is actually coming out at the seal between the gas cap and the filler tube.
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Old 05-15-2019, 12:34 AM #5
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I believe on this one you have to plug the vent tube going to the filler neck if not it will make it seem the gas cap is leaking. I would suggest smoke testing it with the vent tube plugged and inspecting for smoke coming from the top of the tank, the roll over valve may be cracked.
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Old 12-05-2019, 12:49 PM #6
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Updating an old post!
Sorry for the delay in responses. My Gf has been waiting to put the money into any more parts for her 4runner.

So after the smoke test and reading some others similar problems I went ahead and ordered the Gas Fill Neck, which on the 02í is a 4 tube part. Ordered online factory Denso part along with a new Fuel connecting hose, Toyota Dealer part. Total about $200.

So I replaced the old filler neck with the new one. Not a big deal just tedious work. Hardest part was remembering which direction to insert the new neck.

I disconnected the battery to reset code as well.
After removing the old neck and inspecting, Iím a bit concerned that nothing is wrong with the filler neck. As T.Tech quoted, I did not realize that the larger vent tube is not directly sealed to the filler neck. Itís just slipped into the plastic sleeve that wraps around the head of the filler neck and moves freely.
Which in turn may be where the smoke was leaking from during the smoke test. 🤦🏻*♂️
I did not remove or plug the vent hose during the test because I was under the impression it was sealed into the filler neck.

So now Iím worried that the check engine light will again go back on, My Girlfriend will be upset for having to buy more parts, and Iíll have to probably get try again with the Charcoal Canister. Then do what T.Tech suggested and check the Roll over valve.

T.Tech, would it more likely be the roll over valve or the Charcoal Canister?

The Vent tube on the filler neck is connected to a valve on the Charcoal Canister.

Iím posting some pics of the old filler neck and circled the plastic vent sleeve.
Attached Images
UPDATE SOLVED: Infamous Cel, even with new Dealer Gas Cap-9353d8b8-5793-4446-9f69-336a1c811f8c-jpg  UPDATE SOLVED: Infamous Cel, even with new Dealer Gas Cap-3cf68adf-8bde-4181-987d-484f9a68bbc1-jpg 
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Old 12-05-2019, 01:40 PM #7
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Great Video on how to change Check valve.

YouTube
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Old 12-06-2019, 12:54 AM #8
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It would be more likely that the roll over valve be leaking than the charcoal canister. That video shows were they crack but itís usually not that severe.
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Old 12-16-2019, 02:24 AM #9
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I just installed a new Check Valve, Check Valve Gasket, New vent hose and I replaced the rubber hoses coming from the tank.
The old one float seemed to be moving ok, but Iím not sure if there are any other components inside.

Fingers crossed that the check engine light doesnít go off again. 🤞
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Old 12-16-2019, 11:05 PM #10
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Quote:
Originally Posted by Hollywood1 View Post
I just installed a new Check Valve, Check Valve Gasket, New vent hose and I replaced the rubber hoses coming from the tank.
The old one float seemed to be moving ok, but Iím not sure if there are any other components inside.

Fingers crossed that the check engine light doesnít go off again. 🤞
Did you happen to see if it was cracked?
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Old 12-17-2019, 12:35 AM #11
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just for reference, i replaced my '99's OEM gas cap with a MotoRad MGC825T from amazon that is a good fit, adds the leash, fits tightly, and does not leak.

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Old 12-17-2019, 05:40 AM #12
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Quote:
Originally Posted by Hollywood1 View Post
Great Video on how to change Check valve.

YouTube
Looks like a pain in the butt but if it has to be done...

Did this solve your issue?
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Old 12-22-2019, 07:36 PM #13
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Sorry for the late reply. But thanks for everyoneís recent input. I hope itís helpful to others.

So I went ahead and ordered the new Gas Tank Check Valve, Check Valve Gasket, and New House from Check Valve to Charcoal Canister.
I jacked up the rear and used my big jack stands to give me good enough clearance, removed both rear tires.
I dropped the gas tank using a Jack stand and piece of plywood. Once I dropped the tank far enough to get to the Check Valve I used 2 Ratchet strap tie downs to hold the tank in place and removed the floor jack for better mobility. The tie downs made it much easier.
I swapped the new parts along with new rubber hoses on the 3 lines connecting to the fuel cell, 2 small 1/4Ē hoses and 1 5/16Ē hose.

I used Dielectric grease on Check Valve Gasket and hoses to help ease into place.
Put it all together and reset the computer.
My girlfriend drove the 4runner for 2 days waiting for the check engine light to go back on. At this point she was doubting my ability to fix the problem, yet she is clueless to the amount she would have spent at a regular mechanics shop!
After the 4th day driving we had no CEL return and I took it to get its Registration Renewal Smog Check which was due next month. Another reason why I was stressing to get it fixed. California Smog Check is required every 2 years.
The truck passed Smog and new tags are in the mail! Thank Goodness!!!

Thanks to everyoneís help with my issue. I really appreciate it and it saved us a good amount of money that she would of had to pay to a shop mechanic.

Since Iíve spent so much time under the 4runner, Iím now inclined to fix the other issues I found! Leaky valve covers and blown front shock! 🤦🏻*♂️
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Old 12-22-2019, 08:05 PM #14
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glad you got it solved. Your work and documentation will help others in the future
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Old 12-23-2019, 09:37 AM #15
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Great job. Glad you got it fixed.

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