Injen CAI - CEL Code P0441

[Keely]

Hey everyone:Back at the end of June, DJDoubleLP, celicagirl and the rest of the clubvmx clan helped install an Injen CAI on '03 GT. I've consistently had CELs show up on the 3rd drive cycle ever since, although the car otherwise seems to run well (except that lowered mileage - I'm sure it's not me hitting lift more often). It definitely revs over 2,300 RPM and goes all the way up to redline.I finally had my dealer read the code for me when I went in for my regular servicing (hey, I've been away a lot since the CAI was installed). They provided the print out for me (Document ID#847184) but it doesn't mean a whole lot - I'm hoping for you tuning experts out there to give me some advice.Quote »DTC P0441System DescriptionThe DTC P0441 Evaporative Emission (EVAP) System No Flow During Purge diagnostic monitors the changes in the vacuum pressure in the fuel tank. The powertrain control module (PCM) will command the EVAP vent valve ON, CLOSED, and the vacuum pressure switching valve ON, OPEN, with the engine running. This allows engine vacuum into the entire EVAP system. The PCM continues to operate the purge valve until the vacuum has reached a specified limit, at which time the PCM commands the purge valve OFF, CLOSED. If the PCM detects the vacuum level was not achieved, or the vacuum level increased beyond the specified limit, a DTC P0441 will set....Diagnostic Aids- If DTC P0441 is the only EVAP DTC set, the mostly likely cause is an inoperable EVAP canister purge valve. Inspect the EVAP canister purge valve carefully for faulty connections and erratic operation.- An intermitten malfunction may be caused by a fault in any of the EVAP solenoid electrical circuits. Inspect the wiring hardness and components for an intermitten condition. Refer to Intermittent Conditions.- If the DTC cannot be duplicated, the information included in the Freeze Frame data can be usefuly in determining the vehicle operating conditions when the DTC was first set.- Operating the vehicle in CHeck Mode will increase the ability of the powertrain control (PCM) module to detect engine control system malfunctions. Refer to Check Mode in Service Bay Test.Any ideas and advice would be MOST welcome. Thanks!

[Mavrik]

Well I'm going to advise you on exactly what you posted under Diag Aids and that is replace the faulty EVAP Purge Valve...Depending on what tool you have there (I use GM Tech II) you can trigger the valve in a purge cycle and if you don't hear it click open and closed, then its inop. Your basic code scanner might not be able to do this. All this is unrelated to your CAI... this valve is at the back of the vehicle... unless Toyota put it somewhere else...

[Keely]

So if this is unrelated to my CAI, then it should be warranty work, right?I'll also include what my service invoice states in the relevant section:Quote »32732 [my ODO reading] SES light on scan test and check code P0441 evaporative emission system no flow during purge inspect and check code has aftermarket air cleaner and air intake pipe solenoids hanging and wire tied down couple of vacuum lines plugged off possible customer set codes? when parts disconnected. advised shop foreman and service advisor, leave code chart in vehicle clear codes for now, codes may return.

[Mavrik]

well I can't speak for your dealer but 9 times out of 10 we find the problem with the valve and not with where the air comes in... The fuel system is under a pressure, which gets released by the purge valve or loose gas cap.. none of that is related to your intake at all. When we run that code, I can pretty much say with all confidence, the tech never looks at the air filter.

[MadBill]

On the other hand, if the code did appear right after the CAI install, you might want to triple check all wiring harness and hose connections in the vicinity, JIC you jarred something loose or missed a hose reconnect that the diagnostic system is interpreting as an evap valve failure. Depending on your dealer's attitude, you still might consider removing the CAI before a warranty repair, just to avoid any potential hassles on the subject. (shouldn't take nearly as long as the first install!)

[joatmon]

Quote, originally posted by Mavrik »well I can't speak for your dealer but 9 times out of 10 we find the problem with the valve and not with where the air comes in... The fuel system is under a pressure, which gets released by the purge valve or loose gas cap.. none of that is related to your intake at all. When we run that code, I can pretty much say with all confidence, the tech never looks at the air filter.How many vibes come in with this problem? sounds like a lot. Is this valve a high failure rate item in these cars? What do they cost?My guess would have been that it was related to the CAI, since the CAI install and first CEL happened at about the same time. Maybe there's a vacuum line disconnected or not plugged. Maybe put the stock intake back in to see if the CEL goes away. Sounds like the service record documents the fact that there was an aftermarket intake installed, not sure what that does to warranty coverage.

[teammonkeys]

I think this was the code that I got when I first installed the supercharger. To make a long story short, I got the Mass Air Flow sensor replaced and no more CEL.

[Keely]

So what I'm gathering from most of the above posts is that there are vacuum hoses (solenoids?) that connect or are in the vicinity of the CAI and the EVAP purge valve and something could have been disconnected or is connected and shouldn't be. It's pretty difficult for me to figure out since there seem to be a bunch of unconnected hoses and I have no idea what should be connected to something and what shouldn't be, and if they need to be terminated or not, and if so, how should they be terminated.If there's anyone here with an '03 GT and a CAI install that can possibly take a picture of the EVAP purge valve and the associated hoses so that I can see what it's supposed to look like and compare it to my own install, I would be extremely grateful.