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Hi! I'm new to the forum, registering after having lurked a fair bit. I have done a bunch of searching but decided to create a new thread because I didn't want to revive an old one and didn't see anything quite like what I'm encountering. My car is a 1997 Legacy with 170,000 mile or so. I've had this P0440 code for a year or so and at one point had a shop do a smoke test and they verified there were no leaks. They said the vent solenoid was functioning intermittently and that they could replace it, but for the moment it was working. I didn't have them replace it, passed inspection then promptly got the CEL again and the same code. I read that the code could mean the system is unable to achieve a vacuum, so I pulled the charcoal canister to weigh it. I heard on a youtube video anything over 2.5lbs means that the tank was likely overfilled and gasoline leaked into the canister, which could throw the code. The thing weighs 3.5 lbs. and is currently sitting in the sun to evaporate. I also notice the activated carbon is leaking freely from the purge hole on the canister. Is this normal? AND, when I pointed the dangling purge hose toward the ground, a bunch of activated carbon fell out! I then connected the green diagnostic cables below the dash and checked out the solenoids. The vent valve by the canister appears to be fine (it clicks, although I didn't pull it off to check if I can blow through it), but the purge valve (behind the intake manifold) wasn't clicking, so I pulled it off and applied a charge and verified that it doesn't close at all. It reads around 25 ohms, but if it doesn't close, that doesn't matter, right? When I blow through the vent hose that was connected to the purge solenoid (that I think connects to the canister), it is totally blocked-- no airflow. Should I be able to blow through the hose to where the canister was? I don't have a compressor so I was just blowing with my lungs. Excuse my ignorance, I'm new to cars (mostly worked on bicycles) and I'm trying to understand how this all works. It seems to me the carbon should stay in the canister, so if its leaking maybe the canister's broken? Can it be rebuilt or cleaned? And if the purge valve doesn't close, that needs replacing too, right? What about the hose? Should it even be open with the purge valve and canister removed, or is there anything that would block it in between? Let me know if I can provide more info / clarification. Thanks for your help!
