2004 Prius Check engine light on. EVAP P0446

Discussion in 'Gen 2 Prius Technical Discussion' started by JeffAnd, Jun 18, 2025 at 1:41 PM.

  1. JeffAnd

    JeffAnd Junior Member

    Joined:
    Jul 19, 2021
    33
    5
    1
    Location:
    Wisconsin
    Vehicle:
    2004 Prius
    Model:
    ----USA----
    20250617_220130.jpg My 2004 Prius sat for 4 weeks while I rebuilt the battery. After about 2 days of driving the vehicle the check engine light came on. The diagnostic code pulled was a P0446. This is an evap code. While driving the car the scan tool showed the valve opening to 100%. This is with a full tank. Once the vacuum reached -0.5 PSI it would immediately close the valve. The pressure immediately dropped also. When I did fill the tank, the pump repeatedly would shut off.
    This sounds like a vent solenoid stuck partly open. No other fault codes have been generated so far.
     
    #1 JeffAnd, Jun 18, 2025 at 1:41 PM
    Last edited: Jun 18, 2025 at 1:52 PM
  2. pasadena_commut

    pasadena_commut Senior Member

    Joined:
    May 2, 2019
    2,218
    661
    0
    Location:
    Southern California
    Vehicle:
    2007 Prius
    Model:
    N/A
    Have you seen this?



    Does Wisconsin salt its roads? In areas that do that having actual holes somewhere in the evap system is a possibility.
     
  3. JeffAnd

    JeffAnd Junior Member

    Joined:
    Jul 19, 2021
    33
    5
    1
    Location:
    Wisconsin
    Vehicle:
    2004 Prius
    Model:
    ----USA----
    Yes. I have seen this video. I will be doing a smoke test. This should verify any leaks and proper vent valve function. Before ordering a $90 part i want to verify it's bad.
    My vent valve is very rusty. After 20 years in a salt bath.
     
    #3 JeffAnd, Jun 18, 2025 at 3:26 PM
    Last edited: Jun 18, 2025 at 3:38 PM
  4. JeffAnd

    JeffAnd Junior Member

    Joined:
    Jul 19, 2021
    33
    5
    1
    Location:
    Wisconsin
    Vehicle:
    2004 Prius
    Model:
    ----USA----
    Did the smoke test. The only place smoke came out was by the gas cap, and inside the fender at the top of gas filler neck. I did not see a lot of smoke. It came out some small holes. This looks like the vent for EVAP system. The gas cap will be replaced later today.
    When the engine is running. The purge valve ramps up to 100%. Fuel tank pressure shows -0.5 PSI. I suspect that the vent valve is stuck partly closed or charcoal canister is having a problem. $300 Cost. The vent valve is very rusty.
    20250619_204035.jpg

    The gas cap replacement will not solve the gas pump shutting off repeatedly during a fill.
     
    #4 JeffAnd, Jun 20, 2025 at 12:18 PM
    Last edited: Jun 20, 2025 at 12:29 PM