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How to fix 2001 Toyota Sienna Evap System Error P0446 P0442 P0440 P0441
Other years 1999, 2002, 2003, 2004, 2005  unknown if applicable - anyone?)

Other Useful Sienna Pages.

For help with Toyota Door Handle replacement click here

For help with Toyota Sienna Knock Sensors click here 

For help with Toyota Sienna Oxygen Sensors click here. 

For help with Toyota Sienna Misfire Codes click here. 

Read the Story of our Toyota Sludged Engine Repair.

For help programming your remote door lock fob / keyfob

P0440, P0441, P0442 and P0446 Toyota Evap Problem.- How to Fix Toyota Evap System.


                    

So what does the Evaporation System do anyway? Why do I need it?

Gasoline in your gas tank (and entering the tank) does evaporate a little causing gas fumes, which harm the environment. The evap system essentially collects them, and routes them through the engine to be burned. (Which causes other gases harmful to the environment, but enough said)  A series of valves, both electrical and air operated, are connected to the engine and a "charcoal" vapor canister behind the fuel tank is used to store the vapors until they can be sucked back into the engine through another electrical air valve under the hood, maybe. A pressure sensor in the fuel tank lets the ecm (the van's computer) watch all the associated pressure changes. When things don't change the way they should, the computer sets a code, or four..... P0446, P0440, P0441, P0442 which are about as useful as a sliding door on a submarine, since they do NOT really help you pin down which bit is leaking or failed at all. Now your van is an environmental hazard, won't pass a smog inspection, and all the neighbors will laugh about you. OK so the last bit may not be true always. Mine do though.

Complicated enough for you? The bad news is that leaks anywhere pretty much set the same codes. My problem was one of those circle valves actually on the canister. Your mileage may vary of course - maybe you will have just the "bad gas cap" problem! Let's hope.

 

Your check engine light comes on, you get the codes read and they're P0440, P0441, P0442 and P0446 or a combination. Now what?
Here is the fuel tank on your Sienna. See the oblong box at the top of this picture? That is the Charcoal / Vapor Canister. The Evap System consists of several parts - some under the hood, some connected by long tubes at the fuel tank. The codes are telling us that this system has stopped working or the sensor in the tank thinks so anyway.
A simple fix is a loose or bad fuel cap - as if I would ever get that lucky! One way I knew we had a leak is because that sucking sound when you remove the gas cap to refuel had stopped happening - another clue!

There are 3 electrically operated valves in the system - they only cost about $40 and are easy to replace.
Taking it to the dealer will result (almost certainly) in them NOT just replacing one of these - they will want
 to change the whole canister - $325 parts + a million dollars labor of course. I cannot afford that so I started to look at mine

 

 

Mine, of course,  was NOT the electrical valve VSV (Toyota Part # 90910-12264) -despite the P0446 code which specifies  this.
   I had a perforated or torn air valve at the front of the canister - which you cannot buy separately of course!
 
   Here's a picture of them - they come off - but you cannot buy them on their own
  - You have to buy a whole new canister $340 - Rats! Toyota Part # 77740-08042 (which replaced 77740-08041)
 
  The new part number probably means that the old ones all had a problem ....????.

 

So how did I figure out that the diaphragm on one was bad?
 Without knowing what each valve did, some things are always the true of this kind of valve.

The small hose at the top (and bottom on one) connects to one side of it's valves diaphragm, which means air should not be able to pass through it. One of mine was venting when I blocked all the hoses and pressured the canister (after removing it from behind the fuel tank - there is a plastic cover, 6-8 12mm nuts, the 3 14mm nuts to remove the canister.)

Oh, taking each apart to see the diaphragms is hard - they glued them together - that did not stop me of course. Mine was perished and split in the center.
Still have to buy a whole new canister of course. Shame huh? Third party aftermarket? Forget it! No chance.

Things to check first if you are getting P0440, P0441, P0442, P0446

1) Make sure the gas cap is ON (and "clicks" ) and is the correct Toyota Gas Cap (aftermarket may not work). Clear the codes and run for a while. See if codes come back.
2) Make sure the tube to the electrical valve on the air cleaner is still on - Many clumsy oil change places pull these off accidentally (or on purpose- who knows?)
3) Test and inspect all the rubber lines under the hood and connecting to the canister.
4) Test the VSV Electrical valve on the canister - put 12V across it using 2 small alligator clips and wires (RadioShack) It should click and let air through.
5) Test the other 2 valves under the hood the same way (the one on the air cleaner works backwards i.e. Power = Block Airflow)
6) If you can - test the air valves (seen above) -
7) Bend over - get your wallet out and buy a new Charcoal canister - ouch! $300+ If you are still getting the "whoosh" on taking the cap off, maybe the Pressure sensor in the tank is bad.

Tools used to effect this repair

OBDII Code Reader - Available as low as $39 -You don't need a really fancy one.
12mm & 14mm sockets and ratchet with 6" extension - All usually included in any small metric set
Long nosed pliers - used to remove hose clamps and cable restraints.


So this time I only saved the labor ... oh well.

 TIP - TAKE LOTS OF DIGITAL PICTURES BEFORE EACH PART IS REMOVED!  (USE A GOOD CAMERA WITH A GOOD SIZED SCREEN)

Good Luck with yours!

DavidM

REPAIR RESULT

UPDATE 9/21/09
- The Van passed the emissions test! It took 5 days to complete the Evap Readiness Monitor "drive cycle" in the ECM but as soon as the computer reader (ours is an Actron 9135) said "EVAP Ready" - we had it re-tested and viola. (Note: Since Oct 2008, Texas increased the requirement that only 1 readiness monitor could show "Not Ready" on 2001 and later...)

www.FindOneFindAll.com

Toyota OEM Part# 77740-08042 has replaced 777740-08041
 Vapor Canister for Toyota Sienna:
Make Model Year
Toyota Sienna 01 - 03
 

 

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Po446 Po442 Po440 Po441