Check Engine light question
 

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.

EVAP EMISSION LEAK - '05 Ion3
 

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.

sorry about my response time. i appreciate y'alls help. i have not been able to get back to this yet, so bear with me. i plan to post back one way or other after i finally get to this. goaliemo, thanks for the offer of the filler neck. i will let you know if i need it. plan to unhook battery, do the repair, then drive for awhile to see if chk eng light remains off.

getting back to fixing the "leak" for this P0442 code - I had already replaced gas cap within past year, last weekend i took the filler neck off & put it on my workbench. mixed up plenty of Bondo hardener/resin, then took strips of fiberglass mesh & dipped them. then pressed them onto the tube, wrapping smaller pieces around the bypass tube the extends 90deg out from the top of fillerneck and goes way down to connect to i think the charcoal canister. anyhow, sealed it all up & down. photo here:
The RED arrow points to a mounting hole on the filler neck. beware you cannot see this when trying to remove the tube from the car. i finally managed to remove it (10mm socket). But to avoid having issues putting the tube back on, i took the gas cap shroud off and cut out a shape (shown by RED arrow in 2nd image). this allows straight access with a socket extension.
Unfortunately, after 6 days, the check engine light is back on as of yesterday. The code this time is P0455; so from my research online i just went from P0442 (small leak) to P0455 (large leak); AFTER sealing up the filler neck.

I don't believe cutting out that triangular shape from the shroud would cause and EVAP system / fuel vapor leak. So, i'll be checking with local shops to get another smoke test soon

I need help with the code P0442.
I replaced the gas cap, where should I go from there?

I read on another forum that it could be the fuel filler neck.

Tooter, go out to the Pull-A-Part on Centennial Blvd there in Nashville and get another filler neck. They show to have 3 Ions in the yard. Here's the link with the year and row in the yard that each one is in. Inventory Search Results - Pull-A-Part

You think that's most likely the problem?

most of the time it is the filler neck. They are plastic and we all know plastic cracks over time.

I'm going to go get one today or tomorrow and see what happens.

Any chance it could be the purge valve?

Toots,
Find a write up about how the evap systems have been implemented for s cars and you'll get a much better understanding of how the leak test is run

Ok, I went and got a used filler neck and it has thrown the same code. :(
Either this neck is bad too or something else is wrong.

Not sure where to go now.

Edit: I think I may have got it to work. I'll post later and explain.

Edit 2: I thought I got it licked but, the light came back on today!

Edit 3: Went and had a smoke test done and come to find out the metal EVAP line from front to back has rusted through, so that means the FUEL Line is also rusted really bad and needs replacing too!

Quote I was given for all lines and a small section of rusted out exhaust comes to $757.82 :(

Called local dealer part sources and found the lines for $166.08 & $133.74. Think I'm going to the junk yard and see if I can remove those tomorrow.

New (used) lines fixed my problem. These lines should be rust resistant.

Mine were absolutely horrendous, the EVAP line was so brittle, it feel apart. The Fuel line started leaking as soon as i started moving it for removal.

P0456 EVAP small leak
 

i read Tooter's situation and appreciate the info. i need to check my fuel lines. Here are some great videos on locating a SMALL evap system leak.

Part 1:

Part 2:

The mechanic that did these videos located an issue with the purge valve. My system apparently still has a small leak; however i have completely sealed up my fuel filler neck; and then still had the code show up with failure - small evap leak. I did the vacuum test as this mechanic showed in part 2. But my purge valve held strong (no movement on the vacuum gage, so that is not my problem.

btw, my friend and i did our own smoke test. light a cigar inside of a sealed container with a hole cut into the container so a hand pump can attach and force pressure, which in turn forces the smoke out of the container. (we used a Tupperware bowl with lid & just know ahead of time if you use same thing you will likely burn a hole through the plastic after a few minutes). Attach a tube from sealed container to your intake for the evap system (near the purge valve if i remember correctly). then start lookin for leaks. my system is NOT showing any results with a smoke test. not sure why yet, or what my root cause is. When i get more time, i'll try look at fuel lines, etc.

but i know the smoke was flowing through the system because i took one of the lines of the charcoal canister under back of car & smoke blasted out of it into my face :o i put that line back on, then we kept looking, can't locate any smoke, so i'm pretty certain that my filler neck is good to go since it was showing a smoke leak prior to me sealing it with bondo. i'll try post back soon if i find what's wrong with mine, but i dont' get much time to work on this.

you might have a good ideal there. but what you just said you have some bondo laying around . that bad. i had a body shop and you dont use bondo for any surface with a hole in it. bondo is corse and will suck all water or any thing behine it,with in 2-3 weeks you will see a big lump. you can not use bondo for this but you are on the right track. you could use chopped glass you can buy it in qy or gal, or something better . now this will work great and will set like cement, you might have to check out to make sure that gas will not effect this.

James, thanks for the heads up on the glass crystals. if i find that a leak is where my filler neck is, i will give that a shot. working on other stuff on car today.