2001-2002 P0440, P0442 Info

[hambob]

For all those P0440 and P0442 sufferers out there,

I had a P0440 and P0442 on my 2002 4x4 runner. The fuel filler neck looked rusty, my emissions test was coming and I smelt gas near the back drivers side area consistently. So I replaced the filler neck. It was the culprit. When I was maneuvering it out the breather line broke off way too easily. For all those who might embark on this adventure there are some things that I learned. The filler neck on the 2001-2002 are different than the previous models. Part number is 77201-35700. It costs 300 before taxes. I found it online for 150 but the picture showed that it was the old style filler neck and I wasn't about to take chances. There are 4 tubes in the assembly not 2 like previous models. It will not fit through the filler door like the older style. You do not have to remove the charcoal canister to get it in, even though it may seem like you do. You must be patient and calm and it will go in. I almost took a hammer to the f'ing thing but I took a break and on the following try it went in with no effort. Dropping the spare tire helps alot, the more room the better.

Happy trails.

 

[segafan1989]

I'm gonna hijack this thread with my problem since it is relatable to the original post. On my 2002 I've been getting P0440 and P0442 with no fuel smell anywhere. All hoses are tight and free of dry rotting or cracks. Could the canister be at fault? I've searched and searched and answers are all over the place.

I don't want to throw money at it trying to fix it. I would rather troubleshoot and isolate. I haven't done a smoke test yet (trying to avoid it)

 

[stir_fry_boy]

I'm gonna hijack this thread with my problem since it is relatable to the original post. On my 2002 I've been getting P0440 and P0442 with no fuel smell anywhere. All hoses are tight and free of dry rotting or cracks. Could the canister be at fault? I've searched and searched and answers are all over the place.

I don't want to throw money at it trying to fix it. I would rather troubleshoot and isolate. I haven't done a smoke test yet (trying to avoid it)

Well, it's likely the canister. Other members including myself have gotten those codes and had to replace it. However, sometimes it depends on what climate you are in. If it's hot (Vegas or Phoenix), it can be any cracked piece of plastic that covers the components on top of the gas tank. It could be as small as a pinhole leak in one of the hoses. It could be a gas cap. It also could be a VSV (Vacuum Switching Valve). Start with a gas cap, one from the dealer.

Gas cap is cheap, that's a good way to start.

Download the FSM. That is key. Follow the flow chart for the codes you are getting.

The FSM Will tell you how to test the VSVs.

You may need to smoke the EVAP system (hoses and components atop the gas tank) to make sure there is a leak, however pressurizing the system and quirting soapy water also works.

If you determine it is the canister, go to Car-Part.com and look up fuel tank. Call the wrecking yard and see if they will sell you a canister. Get a lower mileage used one. That's what I did.

 

[segafan1989]

Yeah, I've done the OEM gas cap with no luck. I downloaded the FSM so I'll see what it says. Most people have fuel smells at the rear but I do not, that's why its hard to pinpoint the leak. The truck spent 12 years in Vegas so something may be dried out.

 

[01thunder]

common codes with faulty canisters, especially for 01-02. i found a new OE one on ebay for $300 and change. easy install with all hoses, clamps, valves, etc. the fuel smell is from the valve that is on top of the tank. my truck is not rusty so the neck is fine. the fuel smell is there and caused by that valve that prevents fuel from coming out if the truck rolls.

 

[Jungoes]

same issue with mines ( 2000 limited)
crack is in the same location as shown in this video.
this guy even shows a repair of the canister

https://www.youtube.com/watch?v=kmNIY8dK7sQ

 

[stir_fry_boy]

Yeah, I've done the OEM gas cap with no luck. I downloaded the FSM so I'll see what it says. Most people have fuel smells at the rear but I do not, that's why its hard to pinpoint the leak. The truck spent 12 years in Vegas so something may be dried out.

I never had fuel smells with my canister failure, it was leaking within itself.

When you mention that the truck spent 12 years in Vegas, the shop foreman at Findlay Toyota (Henderson) told me that they frequently see cracked plastic covers or worn gaskets for the fuel pump, valves, etc on top of the gas tank. They see them on all models of Toyotas about your age. Squirt some soapy water on top of the gas tank while pressurized to see if you have that issue. Or you can drop the tank which isn't too bad.

 

[TX4Running]

P0442 and P0440 codes

Both codes active. Any chance the small tear in the gas cap gasket could be the problem? Or does the hose play a role in the vacuum checks? I'm not familiar with which hoses but I did not see any others in the engine bay looking questionable.
Thanks,

 

[phattyduck]

The big hose in that picture that has a bit of oil staining is a valve cover vent hose. That should be replaced/fixed but isn't the cause of any evap codes.

The 01/02 trucks have the evap system mostly under the truck in the back. That gas cap could be your only issue (get a new OEM one), but more likely it is a seal on the gas tank, valve on the top of the tank or something with the hoses/pipes to/from the tank/canister to the engine.

On the earlier trucks (96-00), the canister in the engine bay can crack in the bottom corners - I just repaired mine with some RTV (JB weld would work too) and it got rid of my P0446 and allowed the evap monitor to pass.

-Charlie

 

[TX4Running]

Thanks Phattyduck. Ordered OEM cap. Trying to find part number for the hose. I think it is 12262-62060. Anyone else know for sure?
Looks like cheapest option is ordering from Amayama in Japan.
It looks like it just slips on at both ends? No clamps of any sort needed.

 

[phattyduck]

Yup, no clamps on that vent hose. You might also be able to use generic PCV hose in that location, it isn't too heavily molded.

You might need a smoke machine to find the evap leaks - those are the most annoying to find.

-Charlie

 

[SpartanKing5953]

I have a 2001 Toyota 4Runner SR5, having an issue with engine bog when I accelerate fast out of a stop. Sometimes to the point where the engine shuts off. This issue does not occur if I accelerate slowly from the stop. I've changed out the air filter and cleaned the maf however the problem still occurs. I have a check engine light, vcs, and trac off light all displaying. I have ran a scan tool and the p0440 and p0446 codes have come up, could these be the cause or are they a separate problem? Please let me know if you have any clue on a fix, and if the problems relate to eachother.

 

[phattyduck]

I have a 2001 Toyota 4Runner SR5, having an issue with engine bog when I accelerate fast out of a stop. Sometimes to the point where the engine shuts off. This issue does not occur if I accelerate slowly from the stop. I've changed out the air filter and cleaned the maf however the problem still occurs. I have a check engine light, vcs, and trac off light all displaying. I have ran a scan tool and the p0440 and p0446 codes have come up, could these be the cause or are they a separate problem? Please let me know if you have any clue on a fix, and if the problems relate to eachother.

I'd expect two different issues, unless the evap leak is really large.

Hesitation under load is normally ignition related, so start there. Make sure the spark plugs are the correct (non-counterfeit!) NGK or Denso dual-electrode plugs, check the condition/age of the wires, etc.

For the evap codes, start with a visual inspection first. Next is a smoke test...

-Charlie