06 Ion 2.2 P0442 small evap leak driving me crazy

[saturntuner88]

I have a 2006 saturn Ion 2 2.2L i've been chasing a P0442 Small evap leak for a while now and im done spending money i replaced the gas cap twice with AC DELCO cap replaced charcoal canister with AC DELCO canister along with purge valve canister close valve and fuel tank pressure sensor all AC DElCO parts cleared the check engine light and every time the evap monitor sets the light comes back on. Ive smoke tested the vehicle and there are no leaks any where to be found and smoke is traveling through the system. the car is driving me up a wall and i cant register the car unless i can pass emissions tests OBDII. any help would be greatly appreciated. Also the fuel pump was replaced on recall about a year ago

[fdryer]

What state are you registered in? Mileage? First time for this error code?

[goaliemo]

Check your gas lines as well.

[saturntuner88]

I live in Connecticut and no not the first time for the code been chasing it for about a year maybe a little longer and fuel lines are all good smoke test the whole evap system with no visible leak me and another person looked at it and there's no fuel leaks or residue of a leak anywhere under the vehicle.

[2007_ion2]

I have a 2007 ion 2, about 109000 km on it and I've been dealing with this for a few months as well. Same code, replaced the gas cap twice as well.

Recently I got a letter from gm about this and there's a warretnly that they have in place now for it. I'd contact them if I was you

[bern]

Are you connecting smoke machine to the service port or the filler pipe? How much gas is in the tank during test?
If high fuel level is covers the end of the filler inlet inside the tank, the smoke will be blocked.

Are you able seal the system with scan tool and do a flow test?

Inspect the top of the filler pipe for end cap (not gas cap) tabs crack and cause a leak. So the end cap is snap on to the top end of the filler pipe with a seal between the end cap and the pipe. The gas cap is attached to the end cap. the 4 tab are one outside of the end cap about 1/2" from the end.

[mdwallace1]

Originally Posted by saturntuner88

I have a 2006 saturn Ion 2 2.2L i've been chasing a P0442 Small evap leak for a while now and im done spending money i replaced the gas cap twice with AC DELCO cap replaced charcoal canister with AC DELCO canister along with purge valve canister close valve and fuel tank pressure sensor all AC DElCO parts cleared the check engine light and every time the evap monitor sets the light comes back on. Ive smoke tested the vehicle and there are no leaks any where to be found and smoke is traveling through the system. the car is driving me up a wall and i cant register the car unless i can pass emissions tests OBDII. any help would be greatly appreciated. Also the fuel pump was replaced on recall about a year ago

1/22/2016: I also had a similar condition just recently on my 2007 Saturn Ion (P0442) (210K miles and live in Michigan). I replaced the charcoal canister solenoid and the purge solenoid in the engine. None of this fixed it. I was about to take it in for a smoke test (there is no emissions testing in Michigan and the car ran fine but the light bothered me.), but another more pressing problem came up.
My car would occasionally go into limp home mode with P1516 which said the Throttle Actuator Malfunction. This was annoying since it wouldn't go over 50mph and ran extremely rough. I read posts and said to clean the throttle Body. I removed the throttle body from the intake manifold, cleaned all the carbon gunk from it and before re-installing, I lubricated the "o-ring" between the throttle body and the intake manifold. Well what do you know, both codes have gone away and my car seems to have more pickup that I haven't felt in a long time. I probably had a small leak somehow between the throttle body and the intake manifold. Cost was a can of Seafoam throttle body cleaner.

(By the way, I also fixed an oil leak that was getting on my serpentine belt by replacing the crankshaft oil seal. I you-tubed crankshaft oil seal replacement on 2.2L Ecotech engine....even though the video was of a Cavalier, it worked just the same for my Ion).

Hope this helps someone!

[billysvue]

http://www.homedepot.com/p/Partsmast...8481/203197297 I put this$2 part(plumbing aisle Home Cheepo) on my gas cap, only after replacing my cannister vent valve only to have the code reappear after a few hundred miles.

No code now for 2000 miles .

[Samtherecordman]

Originally Posted by saturntuner88

I have a 2006 saturn Ion 2 2.2L i've been chasing a P0442 Small evap leak for a while now and im done spending money i replaced the gas cap twice with AC DELCO cap replaced charcoal canister with AC DELCO canister along with purge valve canister close valve and fuel tank pressure sensor all AC DElCO parts cleared the check engine light and every time the evap monitor sets the light comes back on. Ive smoke tested the vehicle and there are no leaks any where to be found and smoke is traveling through the system. the car is driving me up a wall and i cant register the car unless i can pass emissions tests OBDII. any help would be greatly appreciated. Also the fuel pump was replaced on recall about a year ago

Had similar problem ..... I changed the Emission Canister Purge Solenoid Valve for a Brand New One and It fixed my problem. No more Check Engine light.

http://www.saturnfans.com/forums/sho...ighlight=P0442

[dffr1]

04 ion3 2.2

replacing the gas cap fixed it !! 3 weeks now no lite

bought a cheapo from pep boys for $5 - even they said it may not work. first tried the rubber o-ring listed , then some window type seal - just to see if it worked but it did not.

did notice that the new cap wiggles less then the old.

[cg40]

I'm having the same exact issue. What gas cap from Pep Boys did you buy? I don't see a $5 gas cap on their website.

[Citation84]

Just had this problem: Cracked filler neck and associated parts.

Had replaced the gas cap with a GM Delco one and that worked for a few months.

No light since, but...........

[rowdydog]

I had p0496 code, for long time, changed fuel cap , no luck, final bought a evap purge solenoid that mounts at engine, fixed it, had Tech 2 hooked it up b4 and after changing definite bad part.

[Northerner]

I got this dreaded code on my 2.2 manual trans 2004 Saturn Vue. Just popped up yesterday for the first time.


Looking at this thread it looks like there is no clear-cut answer to this nuisance??

[Bill Murray]

Yeah I'm back to chasing this again also.
I've gone over the plumbing from tank filler neck to canister to engine and don't see any visual problem. Tightened all clamps.
Replaced the cap and the evap solenoid on the engine.
Still not fixed.

You can buy a smoke generator on Amazon for about 120 bucks, I've run into this on enough vehicles that I'm about ready to get one and hope it will pinpoint the leaks.

Good luck.

https://www.amazon.com/gp/product/B0...LVDNA8EY&psc=1