There’s gotta be a way to fit up a newer, easier to get, cheaper, Toyota “under rig” canister to the engine bay location…maybe?
There is always a way to do a thing. But until somebody does it, and documents the procedure, and tests it for functionality… it is uncharted territory.
The ‘03+ 100 series charcoal vapor canister, located by the spare tire, is not cheap… $450 from Toyota and $400+ aftermarket.
Now, let me preface this by stating that I have not yet performed a charcoal canister rejuvenation procedure… and the charcoal canister that I describe here to rejuvenate is for a Pre-‘03, which is located in the engine compartment, but I maintain that it seems that the most cost-effective and positive results manner by which to do this is… follow the documented charcoal replacement method as described in this thread. There are guys who have done this, and it works. Except the manner in which they seal up the charcoal canister seems to be substandard, because they have documented failures in the sealing method. And I truly appreciate their honesty because that’s how we, as a collective, improve a method of procedure.
Our's is an 01, LX, with the charcoal canister in the engine bay (not in the back above the spare). This mod is definitely more applicable to those model years with charcoal canister in the front, though it could easily be adapted for the later years with the canister in the rear.
I have an aux fuel tank in our hundy - and its a gravity fed aux tank from Front Runner. It sits in the area above the spare tire hoist. Because of this, it is very easy to flood the charcoal canister since the new "full level" of the gas tank is above the outlet from the stock gas tank to the charcoal canister...
I would not holesaw holes on the sides… I would surgically open at the factory bottom seam using an oscillating tool and a bi-metal blade. And use clamps or tape to hold the unit closed until you finish cutting open the bottom seam… that way the springs inside will not cause the unit to forcibly open itself up on you.
One crucial step that I would change, I would not use any JB Weld or sealer to close up the assembly after I was done with the rejuvenation of the charcoal and the cleaning of the internal valves. I would plastic weld the assembly back together, so as to ensure a structurally sound and permanently leak-free finished product. The same way the factory did it… plastic welding.
Cost for this charcoal canister rejuvenation is less than $100 worth of high grade aquarium charcoal and some cleaner for the internal valves, plus the cost of a hot air plastic welding machine… You can pick one of those up at Harbor freight for less than $100… or get the professional model from Leister for $500+… but that choice depends upon your tool junkie status.
When it comes time for my charcoal canister to be replaced or rejuvenated, that’s how I’m gonna do mine.