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Old 03-11-2022, 07:47 PM #16
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@negusm Thanks for the thorough writeup my 01 is at 220k it might come in handy.
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Old 03-11-2022, 08:52 PM #17
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Quote:
Originally Posted by MStudt View Post
I'm guessing it was most likely your charcoal canister rather than the check valve gasket. If the gasket were bad you would smell gas every time you filled up. Side note, replacing the charcoal canister and not the gasket at the same time would most likely result in that gasket failing shortly after. So it's a good thing you replaced the gasket during this process.

Also, there are a couple different part numbers for the rear charcoal canister, and it's important that you match the correct one to your vehicle. If you use the incorrect one you'll have a hard time starting it the first time after filling up, and it will progressively get worse.

Mike
Cool, you could be right that it was the canister...after 20 years, I decided, it's just not worth figuring it out. Everything was suspect.

Can you post the alternate part numbers for the canister? It helps people out. I did not find any other part number for 2001-2002 and it's supposed to be for all trim levels. "77740-35482" does replace a prior part number "77740-35481" but the old one, if you find it, should work.
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Old 08-19-2022, 05:36 PM #18
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@negusm Thanks for the thorough writeup my 01 is at 220k it might come in handy.
Thanks again @negusm , 5 months 5k mi my turn.
I ran my VIN made 11/00 Olathe Toyota web site 82 replaces 81 either will work @ $328 now.
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Old 10-06-2022, 02:59 PM #19
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Question Hose Diameter

Hey first off thanks for all the great information! I was talking to a tech at my local dealership the other day and I had mentioned I wanted to go through and start replacing my fuel system and evap system. He mentioned to look up nylon hoses instead of going with the traditional tubing but I would just need to figure out the inner diameter of the current hosing. Do you by chance happen to know what it is? I'm afraid of pulling a line off and breaking it and then leaving my vehicle stuck sitting there until everything is ordered and arrives. TIA!
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Old 11-16-2023, 05:43 PM #20
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Finally got around to it.

Using should of spent parts list shopping around now costs $808.46. Not bad considering.
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Old 11-17-2023, 11:32 AM #21
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Quote:
Originally Posted by MStudt View Post
I'm guessing it was most likely your charcoal canister rather than the check valve gasket. If the gasket were bad you would smell gas every time you filled up. Side note, replacing the charcoal canister and not the gasket at the same time would most likely result in that gasket failing shortly after. So it's a good thing you replaced the gasket during this process.

Also, there are a couple different part numbers for the rear charcoal canister, and it's important that you match the correct one to your vehicle. If you use the incorrect one you'll have a hard time starting it the first time after filling up, and it will progressively get worse.

Mike
I'm wondering if the Check Valve is my issue? I'm getting no codes, but sometimes I get a strong gas smell around the fuel filler neck. Its REALLY bad when I go offroad, but it happens every once in a while.
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Old 11-17-2023, 04:00 PM #22
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Quote:
Originally Posted by shadow247 View Post
I'm wondering if the Check Valve is my issue? I'm getting no codes, but sometimes I get a strong gas smell around the fuel filler neck. Its REALLY bad when I go offroad, but it happens every once in a while.
That is most likely the check valve on top of the tank.

Mike
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Old 11-20-2023, 05:02 AM #23
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Quote:
Originally Posted by shadow247 View Post
I'm wondering if the Check Valve is my issue? I'm getting no codes, but sometimes I get a strong gas smell around the fuel filler neck. Its REALLY bad when I go offroad, but it happens every once in a while.

Is your EVAP readiness monitor set? If it’s not it will not code EVAP issues.


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Old 12-23-2023, 06:26 PM #24
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P0440, 0441, 0446 Codes

Thanks for the great write up! I currently have 3 codes and the smell of gas outside of the car. Additionally, several months ago I was off-roading and on a steep incline and smelled gas. I looked under the car and saw a stream of gas flowing out of the top of the tank.

I've spent the weekend diagnosing potential issues using the tests found in the FSM and another thread titled: "P0440 Fixed!". A fuel tank pressure test revealed that a large amount of air was flowing from the check valve. I put my hand through the hole in the floor under the back seat and felt air coming from the check valve. I also performed a test to check the check valve and it failed. I also tested the VSV on the charcoal canister and it failed (it was as if there was no longer a valve inside). While the charcoal canister was out I performed pressure and vacuum tests on the canister. It passed the pressure tests but failed the vacuum ( I was not able to achieve any vacuum). The charcoal in the canister can also be easily heard when moving it or shaking it.

I've come to the conclusion that my check valve/gasket is shot and the charcoal canister needs to be replaced. Due to the cost of canister I'm planning on fixing the issues on the tank first and going from there. I've ordered a new check valve/gasket and a cut-off valve. I'm having trouble finding a gasket for the cut-off valve and appreciate any help! If there are any suggestions as well please feel free to share.
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Old 05-03-2024, 10:25 PM #25
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Quote:
Originally Posted by camelyk View Post
Hey first off thanks for all the great information! I was talking to a tech at my local dealership the other day and I had mentioned I wanted to go through and start replacing my fuel system and evap system. He mentioned to look up nylon hoses instead of going with the traditional tubing but I would just need to figure out the inner diameter of the current hosing. Do you by chance happen to know what it is? I'm afraid of pulling a line off and breaking it and then leaving my vehicle stuck sitting there until everything is ordered and arrives. TIA!
Hey, going to replace the hoses too while doing this on my 2002, you get the sizes figured out?

It mentions 6 mm and 8 mm earlier in the post... I measured the OD of some of the hard line to hose tubing and it was all over the place, like 6.5 mm - 10.5 mm...
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Old 05-06-2024, 12:05 PM #26
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Quote:
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Hey, going to replace the hoses too while doing this on my 2002, you get the sizes figured out?

It mentions 6 mm and 8 mm earlier in the post... I measured the OD of some of the hard line to hose tubing and it was all over the place, like 6.5 mm - 10.5 mm...
I too went down the hose diameter journey to no avail.

I ended up buying a set of mixed diameter fuel hoses from Jeff Bezos that ranged in different sizes and chose the size that best fit and attached with worm clamps.

I believe it was 3/16th or 3/8th? Something along those lines.
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Old 05-08-2024, 11:28 AM #27
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Quote:
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I too went down the hose diameter journey to no avail.

I ended up buying a set of mixed diameter fuel hoses from Jeff Bezos that ranged in different sizes and chose the size that best fit and attached with worm clamps.

I believe it was 3/16th or 3/8th? Something along those lines.
Thanks for the heads up, going to have some brass 8mm/10mm nipple adapters ready for the mixed size hoses.

Otherwise, I bit the bullet and ordered OEM hoses, not all of which are available, so there will be some hose rigging.

Will report back on sizing for my CA 2002.
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Old 05-21-2024, 01:20 PM #28
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Many thanks negusm for this post, VERY helpful and good advice!

Just finished tank drop fuel delivery / charcoal canister replacement.

There were no codes on my truck, but at 22 years old, I am replacing items like these.

Totally agree with the points negusm makes with the parts lists if you can afford it, especially with the charcoal canister, that thing would be a can of worms to replace hoses etc.

All lines were just cut in this case to ease removal.

I opted to replace the Fuel Filler Hose 77213-35360, and the fuel filter.

Reused the existing Fuel Pump Cushion 23249-74610.

Using the fuel pump to drain the tank helped make it more manageable.

Alligator clips to the two terminals and a battery, +/- shown activates the pump, and with the flexible fuel line disconnected it can be directed into a container.

While the tank was out I cleaned the inside of the tank and painted the skid plate / tank exterior.

Cleaning the tank interior was essential for me since the gaskets crumbled during removal. It was pretty clean and no rust. Used KBS Coatings 2400 KBS Klean for cleaning, then lots of rinsing and air dry overnight.

The tank has some type of outer coating, maybe an epoxy based undercoating, it was more chemical resistant than the wheel well coating. Wire wheel --> Maroon scotch brite --> degrease --> Eastwood rust encapsulator on rusted areas --> Raptor tough undercoating. (the Raptor is a good coating, but the nozzle kept clogging, beware)

Lastly, as negsmn states, all lines needed are a combo of 6 mm and 8 mm. The / any 10 mm lines come with the charcoal canister assembly.

Check out the hose sizes and approx lengths with part numbers in the attached drawings. A few hoses were discontinued, but were easy enough to size with off the shelf fuel line.

I used vac grease only on vac lines, and a little oil on any lines that carry fuel.

Off to smog soon, and these systems should be good for another 20 years if I am lucky.

Appreciate y'all!
Attached Images
Fixed my P0440 Evap code too!  2002 SR5 4x4 - COMPLETE FUEL AND EVAP PARTS LISTS-img_2872-jpg  Fixed my P0440 Evap code too!  2002 SR5 4x4 - COMPLETE FUEL AND EVAP PARTS LISTS-2002-4runner-vac-vent-lines-fuel-tank-jpg  Fixed my P0440 Evap code too!  2002 SR5 4x4 - COMPLETE FUEL AND EVAP PARTS LISTS-2002-4runner-filler-pipe-vent-tubes-jpg 
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Last edited by Late_Night; 05-25-2024 at 12:48 PM.
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Old 05-24-2024, 09:23 PM #29
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Glad this has helped people.

Still no codes!

I've driven her 290k miles and counting (minus a couple of dozen miles from when she was new at the dealership before I bought her). Everything still works! Legendary vehicles.
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Old 06-28-2024, 02:00 PM #30
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Went through all this too

Quote:
Originally Posted by negusm View Post
Part 2!

So, next I was going to deal with really the only other two areas under the car that would cause an evap leak. The charcoal cannister and its mess of hoses. The filler pipe and its connections.

Parts for the fuel fill tube and charcoal canister:
Code:
Filler Cap 		77300-53010 	1 	$21.45 <- Often the culprit.
Grommet, Screw 		90189-06212 	4	$4.12 <- You will break most of them.
Vapor Canister 		77740-35482 	1 	$297.57 <- All hoses were cracked and suspect.
Hose Sub-Assembly Fuel 	77404-35010 	1 	$24.31 <- Flimsy.  Buy a new one.
*Filler Pipe 		77201-35700 	1 	$183.06 <- Inspect and test vent tubes.
*Fuel Pocket Seal 	77391-14020 	1 	$2.01 <- Not needed.
*Ring 			77391-35010 	1 	$2.72 <- Not needed.
*Filler Pipe Shield 	77291-35060 	1 	$34.06 <- Not needed.
So let's do some totals.
Total for parts I spent: $569.30
Total for parts I'd recommend: $347.45

Again, I went overboard with the parts.

Toyota does sell a gas cap seal/grommet so you can try that route instead of a whole new cap as it's a little cheaper and you can always just replace the cap later.

The Vapor Cannister and its myriad of hoses, etc, is an absolute mess:



Once I had my old one out, I feel good about plunking down $300 to replace it. The contents rattled around inside unlike the new one. Every last hose had cracks in them and they would ALL need replacing. Also, I'd have to spend time troubleshooting the valves, etc. to make sure they worked and they looked beat. By the time I got a new canister, replaced the hoses, what would I save? $150? It's just not worth my time.

The filler tube was a different story.



It is mostly metal except for one piece near where the gas cap goes. I can't see it going bad, but maybe there could be some leakage where the green tube is pushed into the grey plastic (see picture). I would remove this unit from the car, inspect it for issues. Then remove that green tube, grease it with vacuum grease and reinsert. This is not super hard to change out if it winds up being the issue. Older 4runners I don't think have this or at least they have a few less tubes.

The other parts I bought that I didn't need was the fuel pocket and its two metal rings that hold it in place. Oh well. I thought it may need to seal something. The fuel pocket with new gas cap looks awesome though!

Part 3 coming up!
Yes, but did you get the check engine light to go off? And did it pass smog?
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