My daughter's 03 Ion is throwing a PO442 code "small leak detected" the freeze frame data shows Fuel sys 2 CC Fault.
Any ideas how to narrow this down ? I really hate throwing money at things 'cause it might be.....
Thanks.

 

Could be any part of the fuel system including the fuel cap ...

 

Yep -- a loose fuel cap will trip that error, sure enough .....

 

+2 remove and re-seat fuel cap

 

Thank's I will try a new cap , I cleared the code a few weeks ago and the CEL came back on.
I guess the cap is the cheapest place to start......
Thank's again.

 

Thot i'd add to this thread, since I've have had this P0442 code over past 1-2 years. About a year ago, i replaced my gas cap with OEM and the fault code cleared and stayed gone for maybe 1-2 months. Then returned. I paid a local shop to diagnose for me couple days ago, and they did a smoke test. They found smoke escaping from the fuel filler neck - just 2-3 inches below the top of the neck where it passes thru the fender well to the cap location.

To resolve this, first thought i had - 1) remove fender well splash guard and 2) apply some type of adhesive or sealant directly to the neck, surrounding the entire area. I have some material left from a Bondo fiberglass repair kit; so i thought about trying to wrap that material around the neck and apply the resin / hardener.

Anyone tried repairing the fuel filler neck like this or another method? instead of replacing it?

 

Not me. I've replaced the entire filler neck on my Grand Caravan. It's not that difficult to do. I do find it interesting that you have revived a topic that's damn near six years old, though!

 

wow, i just noticed the 2009 dates on the thread & it has been nearly 6 years. i was thinking more of the expense of the part, so repairing appeals to me. i glanced and saw these filler necks listed for around $50-$60 ish; but i need to find time to look again & i may can locate close to OEM as i can for a bit cheaper. i hope to have time to dig more this weekend.
Before i attempt to use the chemical mix repair near the fuel tube, i'll have to read up on the Bondo label. i would assume that i can remove the filler neck and do the repair on my workbench & let dry. once dry i would not think the mesh material & resin/hardner would be a fire hazard near the fuel line.

 

I'm pretty sure you'll be okay on doing the repair they way you described, Dennis. That's how I'd go about it if it were me. I looked at the Pull A Part site in Nashville and they don't have any 05 models. They have 4 2004 and 1 2003 Ion. If you can find out if they're all the same part #, maybe I could grab you a good one and ship it to you.

 

I have one I can sell cheap.