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Hi all,

I checked stickies first but couldn't find anything. I could have missed it too.

I know this is a common issue on these cars so I apologize if I'm being redundant.

Long story short the P0440 code keeps coming up for gas cap or exhaust leak.

Things to consider. The first time the tank was filled to the top, gas started pouring from where the filler neck and gas tank meet. The dealer we bought it from used JB weld patch the leaks. Since then no gas has leaked and there is no smell of gas either.

The light did never came on for this. A while after the above what I'm about to tell you happened.

So my girlfriend was driving when the OEM muffler strap broke and the muffler dragged on the ground. She was in the tunnels on 93 in Boston and couldn't stop. By the time she did she had a huge hole in the muffler.

I zip tied it because she didn't have the immediate funds to buy a new pipe and muffler strap. Sure enough after a few days of driving with the hole in the muffler the light came on.

Gas cap is new......it's not the gas cap.

We have since replaced the muffler + bracket. I reset the light after manually by disconnecting the battery to see what would happen. It just came back on.

They entire exhaust system from the manifold to the muffler is new. Not a spot of rust. Courtesy of the previous owner.

The evap canister looks good from what I see and it clicks when I turn the key so it's getting power.

Any help would be great I just don't want to pay $80 for diagnostic for the mechanic to tell me it's a freakin GAS CAP!!

Thoughts? Can post pics if needed.
 

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05 camry 07 tacoma
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"The first time the tank was filled to the top, gas started pouring from where the filler neck and gas tank meet. The dealer we bought it from used JB weld patch the leaks."
A small leak when system pressurized can set P0440.
Replace the patched part if smoke test shows leak.
 
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