P0440 Fixed!

[fourfive]

Thanks so much for writing about this in such detail......Now I need to figure out the P0440 code. I'm going to tackle the charcoal canister this coming Thursday night. So frustrating.

Your welcome! If you haven’t already, test your charcoal canister to make sure it is leaking before replacing it otherwise you’ll still be hunting down the evap leak and be out however much you paid for a replacement canister. Since you have a 2002, look into the overfill check valve gasket on top of the tank. Not really difficult but more involved to replace than the canister and much cheaper.

 

[USMC_Spike]

Added some pages from the FSM that I followed for troubleshooting my charcoal canister and fuel tank for evap leaks.
Charcoal canister and VSV for pressure switching valve location for 01-02 4runners)
View attachment 232379
Disconnecting vent line hose from canister (fitting can be difficult to remove)
View attachment 232380
I used a 9v battery and a multimeter to test the VSV for pressure switching valve
View attachment 232381
How to pressure & vacuum test charcoal canister. You can use a hand held brake bleeder with pump & vacuum option or air from lungs.
View attachment 232382
Overfill Check valve testing
View attachment 232383
Fuel tank & filler neck testing for airtightness
View attachment 232384
Check for proper ventilation on air inlet line on charcoal canister
View attachment 232385

Really good stuff. Keep failing inspections for the same reasons that don't go away.
or that one persistent thing that takes 100's of miles to clear.

I'll be doing this soon and wondered what the referenced page numbers were? I've spend an hour + going through the pdf that's linked, but not
having a TOC or INDEX I can find the pages to print them out.

Also, any from North Texas, Richardson, Dallas, Garland area?

If someone doesn't mind pitching in, I can provide pizza and beer, etc.
My problem is my driveway is 45 degrees. Imagine that. Kind of
eliminates what I can and can't do.

Or Anyone know a good affordable shop in the area?

Thanks

 

[fourfive]

Really good stuff. Keep failing inspections for the same reasons that don't go away.
or that one persistent thing that takes 100's of miles to clear.

I'll be doing this soon and wondered what the referenced page numbers were? I've spend an hour + going through the pdf that's linked, but not
having a TOC or INDEX I can find the pages to print them out.

The page numbers are 922-927 & definitely take it through the specific drive pattern conditions to reset the readiness monitor to pass inspections. Good luck!

 

[paulmofyourhand]

Thank you FOURFIVE for this thread! MY02 had this issue for years and I've finally bit the bullet and swapped out the fuel pump, vent, and fill valve. I'm at 120 miles so far without a CEL.

Edit: spoke too soon. Still getting the same CEL. But, I do I can fuel up without the nozzle stopping every other gallon. When the gas cap is open, there's a noticeable woosh noise. So i'll have to keep looking.

 

[USMC_Spike]

Thanks fourfive,

I got it now, those are the page numbers that I needed.
Maybe you linked it and I didn't see it, where do I find
the drive pattern to reset the 'puter?

I've got 30 days left to fix this issue to have it pass the
inspection.

Before this resets and I can't edit it any longer,
where are the series of SF- pages in the PDF?
I see that I need from SF-39 to SF-46.



Thanks

 

[Jayk2k333]

Do it matter which way the two valcuum hose get hooked

 

[Clifford]

For those interested- I did a refurb on my canister back in 2017 and was easy. Cut it open, checked filter, valves, replaced granules, plastic welded shut with a soldering iron. Easy. Pictures suck but never seen anyone else post a refurb so here goes:
2001 4Runner canister refurb - Google Photos

 

[fourfive]

For those interested- I did a refurb on my canister back in 2017 and was easy. Cut it open, checked filter, valves, replaced granules, plastic welded shut with a soldering iron. Easy. Pictures suck but never seen anyone else post a refurb so here goes:
2001 4Runner canister refurb - Google Photos

Creative fix for the charcoal canister. Never would have thought about that as an option. Since you did it in 2017 I'm assuming it fixed your canister? Do you have a link to the type of carbon granules you used? Was the granules the only thing you replaced? Thanks for posting pics.

 

[fourfive]

Do it matter which way the two valcuum hose get hooked

I'm pretty sure that just about all the factory hoses are preshaped to go on one way.

 

[Clifford]

I just got some high grade aquarium charcoal. This- Search Amazon for- Acurel Extreme Activated Filter Carbon Pellets for Aquariums and Ponds
100oz was WAY more than I needed. Prob enough for 3 canisters or more. Larger than stock granules.
Basically there is not much to the canister. Paper filter inside and granules, spring- everything else is on the outside and easily tested.
Main thing is having good plastic welding skills and heating/folding the plastic for a really solid weld/seal. (easily tested if you have a vacuum pump?)

 

[Clifford]

check the carbon tracking on the sending unit as well. remove the cover where the float is and you can see the carbon track.

Can you explain further? Carbon tracking on sending unit?

 

[fourfive]

Can you explain further? Carbon tracking on sending unit?

I think he's referring to the build up on the fuel sending unit. Post #88 1st, 2nd & 3rd picture shoes how to clean the contacts on the sending unit using a pencil eraser.


My 4gunner restore, refurb and re-work

 

[LadyDi4runner]

Just got the 0440 code myself!

Thank you so very much for the excellent write up on the 0440 fix. My 2001 4Runner has almost 170K on it and I just finished replacing the throttle assy to fix the 1120 code. Second major any :nicethreadart replacement ever (due to breakdown and not just general maintenance!)

Now 100 miles later the CEL goes off and shows the 0440. Thought it might be as simple as replacing the gas cap, but chances are, it will not be.

New rabbit hole for me to enter so early in the New Year!

No matter, I've been very HAPPY with my truck and will continue to maintain it and figure out what exactly is causing the code.

Appreciate your lengthy write up with excellent pictures, no less. I will use it as my guide, as I continue the process of elimination to nail down the root cause.

Will definitely keep you all posted!
This forum has helped me soooo much, over the years, great big THANKS to you ALL!

Best,
LadyDi

 

[Crazy09sage]

Fixed!

Excellent thread by the OP! I used this thread a while back to solve my revolving P04xx codes I’d been getting for little over a year (and subsequently clearing) on my ‘02 T4R.

I didn’t go through the hassle of the smoke machine, though that was genius. After replacing the gas cap did nothing I went ahead and dropped the fuel tank and replaced the seals and components you outlined. Also replaced the PSV on the canister and inspected it while I was at it. Also gave me the opportunity to corroseal and repaint the tank to slow the rust down.

Thanks again!

 

[fourfive]

Great to hear. Getting rid of that code was a huge relief but trying to figure out what the issue was sucked.

 

[John01]

Great thread! I’ve been throwing the 0440 code for about a year now! Replaced the gas cap, cleared the code and a few months it came back. Replaced the charcoal canister, cleared the code and in a couple months it came back. I guess I’ll just have to break down and do a smoke test and keep troubleshooting!

 

[scshack]

Just wanted to comment that I had the following codes P0440, P0441, and P0446 along with the ABS VSC TRAC lights. The gas cap was OEM so I went ahead and purchased a new charcoal canister and replaced it with this part. I also tested the Vaccum Switching Value (VSV) and it was bad. Luckily the new charcoal canister had a new VSV attached along with all the hoses.

When I removed the old charcoal canister, I shook it and you could hear charcoal and particles moving around, almost like shaking a jar full of sand. When I shook the new charcoal canister, there were no sounds of particles or charcoals moving around in the body.

Stockwiseauto link to charcoal canister $279.00 + tax so about ~$300.


Side by side old and new charcoal canister

The codes have gone away for now and I hope they stay off! Just wanted to share with the community.

 

[Texas_Johnny_Bravo]

Thank you for this. My 2001 is doing the same thing. How long did it take to remove the Vapor Canister? I would like to check that before i dish out the $$$ for something that doesn't need to be replaced. I am going to replace the Fuel Pump for sure since I currently have 266K miles on it.

 

[Bertin-S2000]

FSM here

I can no longer access the FSM through TIS as it does not play well with anything but IE and I cannot use IE (our tech services policy). I use Chrome and can access Firefox, but neither is supported. I called TIS tech support and if i had an active account i could use either to view, but you cannot re-up or pay for a new account with anything by IE My last 2 day subscription was in 2015.....I am FSM starved. :-(

I need to see if i can borrow someone's computer and IE and reactivate my TIS account....

4Runner FSM 1996-2002.pdf - Google Drive