'02 Camry P0440

Have you check the roll over valve?

Have not checked the roll over valve - will drop the tank and check

Agree with Jorge. Lower tank and spray soapy water on rollover valve. Most likely will see bubbles but no smoke.

Overfill check valve and or check valve gasket could be cracked Or leaking.

There is a TSB, It says its for the Solara, but it never hurts to check the info there. Seems like the filler neck had an issue where it would build up corrosion and the cap wouldn't seal correctly. Again, may not be the case on your car.

Did you use Factory parts? I agree with the others - check top of tank. I have seen some tanks rust out due to snow melt salt - more of an East Coast thing and not West Coast but worth a look. Pull the rear seat bottom and take a peek thru the access cover plate.

So come to find out the vacuum switching valve at the air box is a dorman - will replace with toyota part.

Hope that is the source of your problem

You need to open and close the valves while hooked up to smoke.I have purchased brand new valves that would not completely seal when opened or closed and very common with Toyotas,even from the dealer.

We did exercise all the valves with the scanner

double Check the operation of the valves usually the purge or vent valve near air box I could be wrong but I don’t think it’s a leak you should be looking for . Have you tried controlling solenoids with scan tool for a little confirmation that circuit maybe ok? remember new means “never ever worked“

Operate the valve in the air box. Leave it in to get it warm….probably not sealing occasionally or simply inop.

I see you specifically wrote “dealer” only next to the fuel cap. I sure hope the valves and canister aren't Dorman… There used to be a mobile diag guy making videos of every bad new Dorman part he found…LOL Don't forget the system tests itself with VACUUM, the smoke machine uses light pressure. A vacuum leak can sometimes actually seal itself under pressure, since plastic and rubber can act…

I agree that the OP should make sure the system will hold vacuum. I had a Camry that another shop had changed $1500 worth parts chasing a P0441. The very first part they changed, a Dorman purge valve was defective. Chevy trucks that have a similar failure that causes a P0440, a gross leak, but it turns out that the purge isn't applying vacuum to the system.

Along the GM route, uncle, I had a stuck FTP sensor setting a large leak fault. If you know how it works...you can fix it :-)

Yes, I had that same failure last week on a Tahoe. I used a slack tube and a hand held vacuum pump to make sure the system held vacuum. While doing that, the FTP remained at zero when the system was drawn into a vacuum. The OP could do the same. Everything on that Camry is right by the Air Cleaner assembly. If he doesn't have bi-directionals, he can pinch or plug the hose at the vent solenoid…

We have not run a vacuum test - will do that - Thank you

Make sure you use a gauge that measures in inches/H2O. It will be difficult to see if you use a conventional vacuum gauge that measures in inches/HG using a hand held pump.

Had a vehicle pass the smoke test down to .010. Had replaced the fuel cap & vent valve. Mode 6 reported constant passes @ the shop. Check engine light illuminated once again and we thru a Purge valve its way which corrected the problem. A big take away was finding out how the PCM conducted the evap system testing. This GM uses a natural vacuum test. Heated exhaust & driving cause a build…

As others have said ,I would check the rollover valve on the tank. That era of car it is a pretty common issue.

Are you able to view tank pressure sensor data on a scan tool to determine if it is within range and reporting accurately?

Had same issue. Was the rust next to rubber grommets on top of fuel tank. Broke the roll over valve when trying to get it out, be careful. Used silicone around edge after v CB leaning and let it set up 24hrs b4 pressure testing. Sure wish I had this forum back then!

I agree with the others, check the top of the tank for rust, it is a common issue But I would also add, have you used a scan tool to confirm operation of the purge, vent and switching valves? Did you perform an evap system test? it is available on many aftermarket scan tools and mimicks the factory techstream test, it is an excellent system test if you understand the evap system. did you…

smoke is a hydrocarbon and is very hard to locate a leak directly on tank sending units or pump rings because the smoke is absorbed in the fuel, I like to use a combustion detector to locate the fuel vapor, they work really good and operate like an ac leak detector, once you start using this you will wonder why you did not know this was available.

P0440 indicates a leak in any part of the entire system. This is how I would approach it. With scanner hooked up and tank between 25% and 75%, vent the system at the cap then replace the cap. Start the engine and go into the evap check function which allows you to manually step through about 8 stages of various solenoid control combos while watching tank pressure. Set units to mmhg. Look for…

Using the Techstream EVAP test is what I always do first on a Toyota. The first scan I took on a 2000 Camry shows a gross leak. It could have been anywhere. I applied smoke at the filler neck I pinched off the air dump port. There was no leak when I viewed the flow meter on my smoke machine. I turned the smoke machine off for about 30 seconds, and the flow meter ball stayed at the bottom after…

The FTP sensor should read about 3.3V with no vacuum/pressure. If you ground the Bypass VSV and the CCV at the same time, and tap the ground side of the purge so it activates, (with engine running) you should see a change in the FTP sensor to about 2V or so…this will verify that all the solenoids work, and that the FTP can change. You're also checking the system under vacuum…