Calling all EVAP gurus - p0441 p0455 - help please (1 Viewer)

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New to me 06 lx470, 283K on the dash, p0441 and p0455 have been intermittently appearing since purchase. I would bet that this was happening before purchase because the only thing new under the hood is the purge VSV, which is some aftermarket unbranded part.

First thing I did was replace the gas cap with OEM (either from partsouq or lexuspartsnow, i dont remember off the top of my head). The codes stayed away for a half dozen trips or so, but are coming back now routinely.

Second thing was to replace the hose going from VSV to TB (pretty rotten looking). No improvement. The other hose (VSV to hard line running back to charcoal canister) looks fine.

Next I looked more closely at the purge VSV. Purge VSV - 27 ohm resistance between terminal 1 and 2 (within fsm spec), operating as expected with techstream utility (no flow while off, suction while on and engine running, air not able to be forced backward through valve).

So at this point, I think that everythhing in the engine compartment is working as it should.

Next I disconnected the hose running from VSV to hard line and pressurized with air. To my surprise, the air came out somewhere in the area of the fill neck. Thinking that I got a bad cap, I cleaned both mating surfaces again and had the same response.

Finally, i ran the EVAP montitor test through techstream. Here are my results.
IMG_20250116_121008167.jpg
IMG_20250116_121017990.jpg


I should note that while running the EVAP system test I was almost certain that I could air coming from around the canister pump module. However, I could not demonstrate a gross leak of pressure or vaccum with smoke or soapy water from that location.

Screenshot 2025-01-16 150930.gif


So I'm a bit stumped here. I have been over the FSM a dozen times and I still am having a hard time wrapping my head around the EVAP monitor results.

First - If the purge VSV is ON (open), why is the system expecting a positive number and not a negative one? Opening the valve exposes the system to vacum, thus prodcuing a negative number, which mine is doing. But the reference values for that field are positive?

Second - is it normal for the gas cap to vent air when the system is placed under pressure like this? I used my shop compressor and an air gun to do it, so I'm sure there was far more pressure than the system ever normally sees.

Third - the air that I think I can hear moving around the canister pump module - this is abnormal, correct? From what I can tell, this should be a completely sealed system. Although it does make sense that if a pump is moving air, that air has to go somewhere. So is it that the pump creates a vacuum by pulling from the system and expelling to the atmosphere?

At this point the only thing I can think to do is to replace the canister assembly. I hate throwing parts at stuff though without having a formal diagnosis first.

What does everyone think?

Sorry for the long post, this issue has me really fired up. I can tell this has been worked on before (witness marks on the canister and the very small hose coming off of it) and clearly it was never fixed, and the damn dealership who did the PPI clearly never hooked techstream up to the rig or else this would have been caught. The only reason it never came to my attention is because the system doesnt throw the DTCs unless they persist for 2 cycles. Meaning that whoever sold it to me put on the new VSV, cleared the codes, and washed their hands of it.
 
Just found the farmore detailed step by step evap leak test instructions in the fsm. Will work on this next week and update with the results.

Comments and experience still welcomed!
 
Gas cap is designed to release excessive pressure. Which may be where HP air you added was escaping. It may also have a leak air from fill neck area of fuel tank.

Very often, EVAP issues, are coming from fouled CC.

When CC flooded with gas, by overfilling gas tank. They don't recover, just get worse. They are noticeable heavier than a new CC. With age these contaminated CC, smell racind. Engine, runs very poorly on hot days. Fuel vapors are often seen, coming out gas cap area.


One sure way to foul a CC in 03-07. Add more gas, after auto pump handle shuts off.
 
Gas cap is designed to release excessive pressure. Which may be where HP air you added was escaping. It may also have a leak air from fill neck area of fuel tank.

Very often, EVAP issues, are coming from fouled CC.

When CC flooded with gas, by overfilling gas tank. They don't recover, just get worse. They are noticeable heavier than a new CC. With age these contaminated CC, smell racind. Engine, runs very poorly on hot days. Fuel vapors are often seen, coming out gas cap area.


One sure way to foul a CC in 03-07. Add more gas, after auto pump handle shuts off.
I wondered about the fuel filter neck. I thought I saw a post a while back about a 0455 being due to that. Where have you seen the leaks occur though? The bleed line is welded to the main neck and the vent line from the tank sits in a collar on the fill neck (I was surprised that it wasn't booted or welded). I can move that joint between the neck and vent line in and out about 1/16" but I couldn't pinpoint any leak there. There also appeared to be a tiny air inlet (?) hole about 1/32" diameter at the 6 o'clock position of the fill neck, just inside the fender.

Something else strange - I noticed that if I over tighten the bad cap, it backs off spontaneously. Is that normal for these caps? Wouldn't that be sunshine if all this is was over a(second) bad cap!!

Next week I'm going to pressure test the evap canister and then work back to the tank. I bet it's the canister or one of the components, but we shall see. Hopefully I don't have to drop the tank. I've also got more gas caps coming lol.
 
Something else strange - I noticed that if I over tighten the bad cap, it backs off spontaneously. Is that normal for these caps? Wouldn't that be sunshine if all this is was over a(second) bad cap!!
Tighten until click heard. keep tightening, it keeps clicking (slipping at certain PSI). They do not back off!
 

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