2007 Toyota Yaris H/B

EXPERIENCED FAILURE OF EMISSIONS EVAP SYSTEM DUE TO WATER INTRUSION THROUGH POORLY DESIGNED COMPONENTS. CHECK ENGINE LAMP (CEL) ILLUMINATED CONSTANT ON DURING HIGHWAY TRAVEL. STORED DTCS OF P043E, P043F, P2401, P2402, AND P2419. INTERNET SEARCH REVELED EXISTING ISSUE IN TSB EG048-07 WHICH NOTES WATER ENTERS FILLER PIPE COVER, CONTAMINATES CANISTER FILTER, THEN DAMAGES THE EVAP PUMP LOCATED IN CHARCOAL CANISTER. REPAIR REQUIRES AN UPDATED FILLER COVER ($6), REPLACEMENT OF FILTER ($50), NEW CANISTER ($600), PLUS 0.5HR OF LABOR CHARGES. APPLICABLE WARRANTY IS 3YEAR/36000MILES. DURING REPAIR REPLACED FILLER COVER, FILTER, THEN CLEANED ENTIRE SYSTEM OF WATER. NOTE: THIS YARIS WAS ALREADY BUILT USING THE UPDATED FILLER COVER P/N. YARIS FAILED THE FOLLOWING TEST DRIVE DONE IN ATTEMPT TO AVOID EXPENSIVE CANISTER REPLACEMENT. FOLLOWED TOYOTA SERVICE MANUAL TO TROUBLESHOOT CANISTER WHICH LEAD TO PERMANENT DAMAGE. THREE BOLTS ATTACH THE PUMP VALVE TO THE CANISTER VIA PLASTIC THREADED INSERTS. THESE INSERTS STRIPPED INSIDE THE PLASTIC, RENDERING THE CANISTER UNUSABLE. REPLACING WITH NEW CANISTER AND RETESTING FOR REPAIR. THIS PORTION OF THE EMISSIONS SYSTEM IS RELATED TO A MANDATED REQUIREMENT. THIS FAILURE SHOULD BE COVERED UNDER THE LONGER TERM EMISSIONS WARRANTY PERIOD AND NOT THIS SHORTER TERM PERIOD. FAILURE OF A $6 COMPONENT RESULTING IN VICTIM FAILURES OF $650 IN ADDITIONAL COMPONENTS IS IRRITATING TO THE CONSUMER AND IRRESPONSIBLE OF THE MANUFACTURER. CUSTOMER HAS ALREADY NOTED THAT THIS EVENT WILL AFFECT (NEGATIVELY) FUTURE VEHICLE PURCHASE DECISIONS. NOTE: THIS FAILURE DOES NOT SEEM TO AFFECT MPG OR OPERATION BUT DOES ILLUMINATE THE CEL. CONSUMERS MIGHT OPERATE W/O REPAIR WHICH WILL CONDITION THEM TO ACCEPT AN ILLUMINATED CEL. THEY MIGHT NOT BE NOTIFIED OF OTHER OBD MALFUNCTIONS AND PARTIALLY DISABLED EMISSIONS CONTROL SYSTEM. *TR