Recently I ran into issues filling up my gas tank. It would stop every few seconds unless I turned the nozzle 90 degrees or so. I replaced the evap canister with a used canister. After that, the first time I filled up it had the same issues clicking off every few seconds, but the second time the issue was gone. This lasted a few weeks then went back to clicking off. Also, another symptom was a decrease in MPG by 2-3 miles which got better while the clicking off issue was fixed. Just wondering if anyone has any ideas or can point me in the right direction. Car has about 220,000 miles. Thanks
What was the reason for replacing the canister? Was a diagnostic performed? Were any error codes detected? Were there any error warning lights on the instrument panel?
An existing thread having some information you can start with is here. Just keep in mind that's a gen 2 thread (2004–2009), so your gen 3 has some differences. The gen 3 does not have a bladder inside the tank, but has an otherwise fairly similar EVAP/ORVR system. When you want to get more accurate information specifically for gen 3, this page explains how: Toyota Service Information and Where To Find It | PriusChat It's possible we've got some gen 3 threads already that are like that gen 2 one I linked, but I'm not remembering any at the moment. Does this car have a history of fuel being 'topped off' after the pump nozzle stops automatically? (Before these symptoms began, I mean.)
Yes the fuel was topped off once shortly before this started happening when the nozzle didn't shut off on it own at the gas station. There are no error codes. I haven't performed any diagnostics I figured I would take the $40 guess with the used canister. I will look into those resources next.
Update to this: I tested purge solenoid and it passed so I replaced the canister 2 and the gas refill issue went away and mpg went back to normal. This page has a diagram of the EVAP system. Scroll down a tad and you'll see it. The purge solenoid test can be found here. Here is a video showing its location. Charcoal canister test can be found here. Here is a video showing its location and removal process(It's time stamped). If those two aren't the issue you can try replacing canister 2. This is a picture of it off my Prius. I replaced canister 2 with the fuel fill tube and the canister air filter all attached. I didn't personally test the charcoal canister I just got a used one from Pick n Pull for $40. When that didn't fix it I tested purge solenoid and when that checked out I just went ahead and replaced canister 2 which I also got from pick n pull for $40 after a little haggling.
That CHARM-project manual site looks pretty nice, but it has mixed up some names of some parts. There really isn't a "canister 2". The car has just one charcoal canister. The part in question is a filter: specifically, the second of two filters that filter air for the canister. That makes it the "no. 2 charcoal canister filter", or, when they fold it with commas to make up a parts catalog, it becomes "filter COMMA! charcoal canister COMMA! no. 2": 77746-47010 Genuine Toyota Filter, Charcoal CANISTER They fold it around commas like that so the key what-is-it word, filter, ends up first. The first filter (the no. 1 charcoal canister filter), which the CHARM folks show as "no. 1 canister", I think is part of the leak detection pump module; I don't know that you can buy it on its own. The thing CHARM shows as just "canister", not "no. 1 canister" or "no. 2 canister", is the only canister there is.
