Need advice on persistent P0441 code—vapor feed hose keeps popping off

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by Steven Saillant, Aug 1, 2025 at 5:00 PM.

  1. Steven Saillant

    Steven Saillant New Member

    Joined:
    Yesterday
    1
    0
    0
    Location:
    Los Angeles
    Vehicle:
    2010 Prius
    Model:
    Four
    Hey all, I’ve got a 2010 Prius with about 250,000 miles. I just pulled the EGR cooler and gave it a thorough cleaning. Before that I was getting a P0401. EGR system and intake/throttle body is all good now and the 401 code is taken care of. Now I’m dealing with a stubborn P0441 code (Evap system incorrect purge flow). The vapor feed hose (part 23826) keeps popping off. Wasn’t having that issue before. Anybody here deal with something like this before? Any help would be greatly appreciated. Thanks.

    upload_2025-8-1_13-59-35.png
     
  2. ASRDogman

    ASRDogman Senior Member

    Joined:
    May 29, 2018
    7,288
    3,805
    0
    Location:
    Florida
    Vehicle:
    2010 Prius
    Model:
    Two
    Are you certain you put everything back correctly?
     
  3. Tombukt2

    Tombukt2 Senior Member

    Joined:
    Nov 29, 2020
    12,348
    2,183
    0
    Location:
    Durham NC
    Vehicle:
    2009 Prius
    Model:
    Base
    Pops off whilst clamped nothing but light flow goes thru there no? What's that 25962 valve seems to me something like vacuum get used they're some kind of way . So somehow you've pressure on this hose or engines rocking pulling it off ?
     
  4. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    26,707
    17,494
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV
    Check the "calibration ID" (a/k/a version) of the firmware in your engine control module.

    If it is anything earlier than 34715400 (for a 2010 Prius—for other years see the "NEW" calibration ID on page 3 of this service bulletin), have the dealer update the ECM to that "NEW" version or later.

    The bulletin also recommends replacing the purge valve; it can have taken damage when the hose blew off.
     
    Steven Saillant and Brian1954 like this.
  5. Tombukt2

    Tombukt2 Senior Member

    Joined:
    Nov 29, 2020
    12,348
    2,183
    0
    Location:
    Durham NC
    Vehicle:
    2009 Prius
    Model:
    Base
    So just cleaning the EGR up would create enuff flow to create this or such . Pretty wild . Our 2010bhad all red showing wen I bought it in tech all firmware was way out. I had the updates for all of the internal systems but I was scared to put them in because I was scared of a brick or such . Kaye put 399 on that car with nary a hitch brake lights on two years delivering thru pandemic. She loved that car . That firmware apparently never caused a problem at least to 399K
     
    Steven Saillant likes this.
  6. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    26,707
    17,494
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV
    It needn't have had anything to do with cleaning the EGR, other than happening around the same time.

    Toyota found something in their firmware that, in certain oddball circumstances, makes backfires that blow that hose off and damage the purge valve.

    Georgina spread the word about the bulletin a few years ago, because if it never happens to you, great, but if it does, it could be at a time you don't want your car to be down and waiting for a non-stocked purge valve at the dealer.

    It never happened to me, and I went in and asked the dealer to update the firmware before it ever did, because that seemed better to me than waiting around to see if it would.
     
    Steven Saillant likes this.
  7. Tombukt2

    Tombukt2 Senior Member

    Joined:
    Nov 29, 2020
    12,348
    2,183
    0
    Location:
    Durham NC
    Vehicle:
    2009 Prius
    Model:
    Base
    Yeah well that's a great thing I guess I guess we were lucky Ididnt want to brick the thing because of whatever . Cool you gen3 folks made in China. Com 2zz long assemblies 980 a pop. Yeah I know no low tension rings . I wanna try regular rings . In both 1N and the gen3 2z whatever. Doing the 1n now .