4Runner 4th Gen. 2005 V6 4.0: Gas Fill Pump Constantly Stops; Dreaded Gas Cap Woes

[cchantzis]

I have a 4Runner 4th Generation 2005, V6, 4.0 and need your wisdom about solving the following 2 problems:
1. Gas refilling is almost impossible; the gas attendant has to either set the pump to the slowest possible fill rate setting or restart the fill pump manually every 0.5 gallons or so. Obviously, there is a problem. I replaced the Charcoal canister and vent fuel filter between the charcoal canister and filler neck but so far, no fix. Unless I am mistaken, there is no check/vent valve at the top of the gas tank.
So, what is the FIX please?
2. How To Replace Gas Tank Filler Neck to Non-Toyota Type with with Screw-type Cap

Has anyone done a replacement of the dreaded non-screw type of Toyota gas tank filler neck with a non-Toyota part having a screw-type cap?
Why I want to replace it?
The current Toyota cap design is the root cause of countless fault codes and related CEL problems. The cap design FAILS to seal properly. I have had Volvos for 20+ years and NEVER had an issue with the screw type or threaded cap design.
Some people have posted that the fix is to get a cap from the Dealer or should I write STEALER !??? Yet, I have NEVER seen a photo in multiple angles for the correct design that seemingly SOLVES the dreaded and countless fault code problems. so, pleaseeeeeeee post photos, if you have, or at least post what is the correct Toyota part number.
.
Final question:
Does Toyota sell any car in the US having a Filler Neck and Cap Design of the Screw/Threaded type?
If so, which Toyota type, years, etc.
.
BTW, here is a very nice pdf file on How To Replace a Fuel Filler Neck Part. https://www.tundrasolutions.com/attachments/fuel-filler-neck-replacement-pdf.61603/
.
Thank in advance for any thoughts, even if you have never done this type of replacement.

 

[cchantzis]

Adding to my previous post for completeness:

I only need to replace the gas Filler Cap Shield - Toyota (77291-35130) for ~$42 2003-2009 Toyota 4Runner Filler Cap Shield 77291-35130 ]. I believe there are 2 tubes: the larger one for fuel refill and the smaller one for fuel vapors return. The trick is to match the OD of those 2 tubes with the respective tubing of my car.

People might ask "Have you gotten a fault code due to the gas cap?"
The answer is?

It is TRULY impossible to answer with certainty because apparently Toyota has designed their cars' electronic system to give combinations of numerous codes when in FACT ONLY proper functioning of the gas cap is the ONLY Root Cause!!! I have been studying in depth this problem in various Toyota forums for the last 4/5 years and NOBODY has a PERMANENT FIX Solution, NOBODY!!! I challenge the Toyota manufacturer to post here what is the true root cause and what is the proper solution? Replacement of the gas cap with one from the Toyota Dealership is NOT the proper solution IMO, period. The Toyota Cap Design is FAULTY/under-designed, thereby deficient.
Why?
Because Toyota's cap design depends on only 2 dimples around the cap to properly balance the cap's seal onto the inner lip of the metal filler neck and then seal around the top circular surface of the filler neck. A screw or threaded cap design with a seal provides a seal between the filler neck and the cap without any of the design deficiencies noted above. Simply stated: Can you balance yourself BETTER standing on only 2 Dimples of a circle or standing on a complete circle? ! Obviously, the answer is? Standing on a complete Circle or a filler neck design with screw/threaded cap type.
And Yes, I have tried coating the seal gasket area with Vaseline/grease/lubricious fluids but when I do the "smoke leak test" it still leaks under the gas cap. It is a marginal cap/filler-neck design IMO. That is why I want to find out IF anybody has switched to the screw/thread type of design configuration.

I have a 4Runner 4th Generation 2005, V6, 4.0 and need your wisdom about solving the following 2 problems:
1. Gas refilling is almost impossible; the gas attendant has to either set the pump to the slowest possible fill rate setting or restart the fill pump manually every 0.5 gallons or so. Obviously, there is a problem. I replaced the Charcoal canister and vent fuel filter between the charcoal canister and filler neck but so far, no fix. Unless I am mistaken, there is no check/vent valve at the top of the gas tank.
So, what is the FIX please?

2. How To Replace Gas Tank Filler Neck to Non-Toyota Type with with Screw-type Cap

Has anyone done a replacement of the dreaded non-screw type of Toyota gas tank filler neck with a non-Toyota part having a screw-type cap?
Why I want to replace it?
The current Toyota cap design is the root cause of countless fault codes and related CEL problems. The cap design FAILS to seal properly. I have had Volvos for 20+ years and NEVER had an issue with the screw type or threaded cap design.
Some people have posted that the fix is to get a cap from the Dealer or should I write STEALER !??? Yet, I have NEVER seen a photo in multiple angles for the correct design that seemingly SOLVES the dreaded and countless fault code problems. so, pleaseeeeeeee post photos, if you have, or at least post what is the correct Toyota part number.
.
Final question:
Does Toyota sell any car in the US having a Filler Neck and Cap Design of the Screw/Threaded type?
If so, which Toyota type, years, etc.
.
BTW, here is a very nice pdf file on How To Replace a Fuel Filler Neck Part. [url]https://www.tundrasolutions.com/attachments/fuel-filler-neck-replacement-pdf.61603/

.
Thank in advance for any thoughts, even if you have never done this type of replacement.

 

[morphious]

[MENTION=149483]cchantzis[/MENTION]

Gas filling, I was having the same issue and realized it was the pump at the station I was going to as I was using the same pump. Didn't happen at other pumps or stations, just the one I always used and the issue went away when they replaced the filler.

Gas cap, had a smog check and they found a fault on the original cap and installed a non OEM and haven't had an issue since.

I have had my '04 since 12/5/2003 so 1 gas cap in about 21 years, I don't really see a problem. Just my 2cents.

We have had many Toyota's over the years starting back from 1981 and never remember gas caps being an issue.

 

[cchantzis]

Good day!
I appreciate your suggestions.
The gas pumping station is not the problem because I have tried it with different gas stations without noticing any difference.
I have purchased 5 gas caps and all have NOT solved the problem. I will definitely purchase one from the Stealership and try it out. But, I despise giving money away because a car manufacturer has underdesigned a part. Toyota is notorious for such acts. For example, how many of us have an otherwise perfectly running vehicle but we are FORCED to scrap it because the car's frame is rusted through given Toyota has a frame full of holes - it reduces car weight and saves it money in less used steel - BUT it RUSTS rapidly in the US-SALTED roads!!!
There millions of USD spent every year by US Toyota Owners because of this FAULTY gas cap design and the systemic and SEVERE Rust problem is Toyota's car frames.
Happy holidays!

 

[morphious]

[MENTION=149483]cchantzis[/MENTION] Have you inspected the lip of the filler itself for possible damage or corrosion? Just a thought.

 

[cchantzis]

John,
Honestly, I really don't know yet how to inspect for that issue. Perhaps, I could remove the inside wall panel next to the left back seat and then get access to that area. My research to date points me to the conclusion there is only a gas vent filter between the charcoal canister and filler neck, which I have replaced without realizing any noticeable change. The fact gas can pass-by and fill the tank but at rather slow rate indicates to me the passage might restricted but not necessarily completely blocked-off. If there were to be there some type of check vent valve by the filler neck, then one could theorize that check vent valve could be defective (perhaps its spring mechanism is not operating freely); but I do not think such a check valve exists there, correct?
Thx for springboarding with me about this thorny issue.
Have a pleasant evening.

 

[fastbroshi]

When I gas up, I've noticed sometimes I have to ensure I hold the filler up flush to the filler neck, or else the pump will click off. Not always, but it's like a 50/50 chance that it will. Annoying, but not something I'm going to spend time on figuring out.

 

[Jeebus]

If the pump is stopping as if your tank is full, sounds likely that something is wrong with the breather tube and not enough air is escaping as you gas up, making the pump think your tank is full.

Check the thread - EVAP: What is this line? - by Cezar. Should be on the first page as it's seeing some recent activity

 

[4RuNnMyLife]

If you have access to a Smoke Machine, I would run a smoke test through the EVAP system. I just had to replace my Fuel Filler Neck due to a big leak. If you have the attachment that connects directly to the EVAP Service Port, even better. Otherwise, you'll have to disconnect one of the rubber hoses leading into that service port.

Good luck!