P0440 code mystery, 2001 IS300 - Lexus IS Forum
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post #1 of 20 (permalink) Old 11-10-2016, 08:26 PM Thread Starter
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P0440 code mystery, 2001 IS300

One of the hoses was off near the charcoal canister valve, I secured the hoses and replaced the valve while I was in there. Thought for sure this would fix the P0440 code but the light came back on. I checked the hoses near the purge valve up under the hood and they seem to look ok. Seeing the car is 16 years old should I go ahead and replace the purge valve to see if that resolves the issue? I also already replaced the gas cap in case that was the problem, that's was the first thing I tried. Should also mention it seems like the car is making a bit of a whining noise which I can especially hear when I'm going at slower speeds when going through say a parking lot. Thanks
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post #2 of 20 (permalink) Old 11-16-2016, 11:30 AM
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I am in a very similar situation as you and have already replaced the gas cap and Fuel Tank Overfill Check Valve.

Replacing the Fuel Tank Overfill Check Valve will probably be your next step.

Check out the following link on how to replace it.

https://my.is/forums/f115/01-is300-p0440-pic-433853/
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post #3 of 20 (permalink) Old 11-16-2016, 04:22 PM Thread Starter
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So you replaced the Overfill Check Valve and it didn't resolve the issue?
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post #4 of 20 (permalink) Old 11-18-2016, 02:59 AM
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Originally Posted by Zachj View Post
So you replaced the Overfill Check Valve and it didn't resolve the issue?
It definitely resolved one of the issues because the old one was cracked in multiple places.. I appear to have more than one problem though.
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post #5 of 20 (permalink) Old 11-18-2016, 09:52 AM Thread Starter
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Did or are you having the issue of the car struggling to start after you fill up? I've heard others have solved this by replacing the purge valve, I hear it get's stuck open. I'm going to try that first. It could be the overfill valve but I don't have any fuel smell in the car. I will try this next if the purge valve is unsuccessful.
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post #6 of 20 (permalink) Old 11-18-2016, 02:47 PM
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Originally Posted by Zachj View Post
Did or are you having the issue of the car struggling to start after you fill up? I've heard others have solved this by replacing the purge valve, I hear it get's stuck open. I'm going to try that first. It could be the overfill valve but I don't have any fuel smell in the car. I will try this next if the purge valve is unsuccessful.
No I never had that issue. Let us know if replacing the purge valve ends up working for you.
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post #7 of 20 (permalink) Old 11-18-2016, 03:29 PM
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Did you test the purge valve to make sure it has a good seal when voltage was applied?
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post #8 of 20 (permalink) Old 11-21-2016, 11:26 PM
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In my case, the more I read, the more I am convinced I have to replace the VSV

1987 Toyota MR2
2005 Volvo S40 T5 AWD
2002 Lexus IS300
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post #9 of 20 (permalink) Old 11-22-2016, 09:08 PM Thread Starter
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Not sure why I stopped receiving notification of replies. To answer the question above I didn't test the voltage. I thought about doing this and I should have but became consumed with just finding the part. I've spent a week trying to track down a purge valve at a reasonable price, best I've found is autozone for $72 all other places seem to be over $100. Had to wait for autozones dealer to get it back in stock. Anyhow I finally got the chance today to try and install the new one, stiff frigid winds up here in the northeast didn't make it easy. When I was attempting to remove the vacuum hoses off the purge valve I ended up snapping a nozzle off the expansion chamber(fuel vapor feed pipe) that the hoses go to from the purge valve. The hoses are so old and rigid it was very difficult to get off, and it sounds like from reading other posts that I'm not the only one this has happened to so be careful. I should have heated up the hoses with a lighter to loosen them up. Good news is the expansion chamber, ill post a pic of it, i'm finding it for like 9 bucks all over ebay. In the meantime I have a longer new piece of hose going directly from the new purge valve all the way over to the other connection that the expansion chamber was connecting to. Not even sure you need the expansion chamber but I definitely ordered it anyhow. The main discovery...I previously had looked all around that area very closely to see if there was any damage to the hoses but apparently not close enough! When I got everything unhooked sure enough there was a pretty decent size crack at the end of one the hoses going into the top nozzle of the purge valve that was hidden from the eye unless you had it completely apart. I'm guessing this must be what is throwing the engine light. I'm keeping the new purge valve though just in case the old one is potentially bad. If I had seen the crack I would have just replaced the hose and not bought the new valve. Here's a pic of the crack I found and of the expansion chamber piece. Do you think the crack in the hose is enough to cause the CEL to go on? I will obviously have to complete a drive cycle to see if this turns the CEL off. I did notice that the whining noise I was hearing seems to be much less possibly completely gone. I will have to see if I'm still having the issue with the car having trouble starting after filling up. Either way I will update here when I see if this has definitely worked or not. Be very careful if/when taking those hoses off the expansion chamber! lol I wouldn't take them off there at all if you can.
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post #10 of 20 (permalink) Old 11-23-2016, 01:51 AM
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Thanks for the update and pics! I'll have to check closer at my own hoses.

Yes, I do believe that the crack could cause a CEL.

1987 Toyota MR2
2005 Volvo S40 T5 AWD
2002 Lexus IS300
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post #11 of 20 (permalink) Old 11-23-2016, 10:55 AM
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Alot of time p0440 is casued by the evap canister thats ontop of the gas tank, many people cut a hole under the seat to access.

02 GGP 234k on chassis
BD11A supercharger/dezod headers/greddy catback/bc264/hks cam gear. 285whp [email protected]
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post #12 of 20 (permalink) Old 11-23-2016, 11:19 AM
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Quote:
Originally Posted by az989 View Post
Alot of time p0440 is casued by the evap canister thats ontop of the gas tank, many people cut a hole under the seat to access.
That's the Fuel Tank Overfill Check Valve

1987 Toyota MR2
2005 Volvo S40 T5 AWD
2002 Lexus IS300
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post #13 of 20 (permalink) Old 11-23-2016, 03:14 PM
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Get the system smoke tested Before you throw more time and money at it. The smake test will show where it is leaking.
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post #14 of 20 (permalink) Old 11-23-2016, 06:01 PM
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Quote:
Originally Posted by nightsky.fusion View Post
That's the Fuel Tank Overfill Check Valve
what youre thinking of can be accessed from the trunk under the liner.

02 GGP 234k on chassis
BD11A supercharger/dezod headers/greddy catback/bc264/hks cam gear. 285whp [email protected]
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post #15 of 20 (permalink) Old 11-24-2016, 12:43 AM
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Quote:
Originally Posted by az989 View Post
what youre thinking of can be accessed from the trunk under the liner.
No that's the VSV lol. The Fuel Tank Overfill Check Valve is the one on top of the gas tank. I did that exact process of cutting under the seat a few weeks ago.

1987 Toyota MR2
2005 Volvo S40 T5 AWD
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