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Code P0442 check engine light on, gas tank not purging, trips full sensor on gas pump

Tiny
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  • MEMBER
  • 2004 PONTIAC SUNFIRE
  • 2.2L
  • 4 CYL
  • 2WD
  • MANUAL
  • 120,000 MILES
P0442 Code check engine light on

1 Replaced the gas cap - made no difference.

2 Replaced the solenoid purge valve next to engine (aftermarket Napa Echlin) and it seemed to fix it for about 6 weeks, check engine light went off, was able to fill tank once normally.

3 Check engine light came on again, P0442 Code again, this time replaced the canister purge valve next to charcoal canister - check engine light turned off. There was no smell of gas and no pellets, tubing from canister to valve was clear.

4 A few days later tried filling tank - same issue gas pump clicks off over and over again.

what should I do next?
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Saturday, March 13th, 2021 AT 9:38 AM

19 Replies

Tiny
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Hi,

The canister vent valve (#6 in pic) either is blocked or not working. Number 7 in the pic is the vent hose. When filling the tank, air needs to escape. If it can't, fuel can't enter. Check to make sure the vent hose isn't pinched. Also, let me know if the vent valve is what you replaced.

Take care and God Bless,

Joe
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Sunday, March 14th, 2021 AT 8:30 PM
Tiny
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Yes, I replaced the canister vent valve and the vent solenoid. The check engine light has gone off after replacing the canister vent valve but tank still is not vented. I removed the hose completely between the canister and the canister vent valve when I replaced the valve. The car is due for emissions test next month so I am down to the wire. The only thing I haven't replaced at this point is the canister itself. They are supposed to "last the life of the car" according to research.
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Sunday, March 14th, 2021 AT 9:00 PM
Tiny
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They can last the life of the vehicle, but that doesn't always happen. I've seen them full of fuel from people overfilling the tank. At that point, they are done. If you disconnect the vent hose, does fuel enter the tank normally? Also, are there any codes still active?

Joe
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Monday, March 15th, 2021 AT 11:31 AM
Tiny
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I ran the OBD checker on it and the I/M says everything is okay. It still shows the previous DTC's, not sure if they are historical or "active". My first time using an OBD. I am having the AZ emissions done this week. Will let you know the outcome of that.
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Tuesday, March 16th, 2021 AT 9:04 PM
Tiny
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If you haven't cleared the codes, it may take several miles for them to clear. If you clear them now, it will reset all the emissions modules and then won't pass inspection until they are all cleared. If the scan tool indicates IM readiness, it should be okay. I'm not real familiar with AZ emission laws.
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Wednesday, March 17th, 2021 AT 6:38 PM
Tiny
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Car just passed emissions. They do some kind of gas cap test with some gadget they put onto the gas filling hole. I haven't tried filling gas tank since last week. We Will see how it goes at next fill up. I also noticed another possible symptom - popping ping noise from rear of car. Sounds almost like air suddenly expanding inside an aluminum or plastic can. Will let you know how next fill up goes.
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Friday, March 19th, 2021 AT 9:15 PM
Tiny
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Great, that's good news. I'm glad it passed.

Take care and let me know if you need help with anything.

Take care,
Joe
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Friday, March 19th, 2021 AT 9:41 PM
Tiny
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Well, here I am again! I just filled my tank with gas and it still isn't working. Pump clicks off continuously. I guess my next step is replacing the canister itself.
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Monday, March 22nd, 2021 AT 12:06 PM
Tiny
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What happens if you disconnect the canister?
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Monday, March 22nd, 2021 AT 6:10 PM
Tiny
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Right before filling up?
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Monday, March 22nd, 2021 AT 6:47 PM
Tiny
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That is what I would do. It will set the check engine light for an EVAP leak if you run it like that. I know this is a lot, but go to the pump, disconnect the canister, fill it up, and then reconnect. That way, it won't set a code.

Let me know what happens. If it still doesn't work properly, we have something plugged.

Joe
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Monday, March 22nd, 2021 AT 8:06 PM
Tiny
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I installed a new Acdelco canister. There was only a faint smell of gas when I removed the old canister. Nothing came out of the old canister when I tipped it over. We will see what happens at my next fill up.
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Saturday, March 27th, 2021 AT 3:30 PM
Tiny
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Hi,

Thanks for the update. Let me know what happens. I'll keep my fingers crossed for you. LOL

Take care,
Joe
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Saturday, March 27th, 2021 AT 6:59 PM
Tiny
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Well, just attempted my next fill up. Pump clicked off within 2 gallons, but I slowed the stream down and was able to fill the tank at a slow rate without a click off. It's improved but not fixed. When I pump the gas you can hear the gurgling get louder right before it trips the pump off.
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Wednesday, March 31st, 2021 AT 11:52 AM
Tiny
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Hi,

The sound gets louder because the fuel is raising up the filler tube. If you had it disconnected and it only helped a bit, then the problem has to be before the canister. At this point, you will need to remove the fuel tank and check the fuel limiter vent valve on the tank. I have a feeling it is stuck closed or partially closed.

The attachments below provide the directions and pics relevant for the removal and replacement of the fuel tank and the fill limiter vent valve.

If it is still doing a similar thing, either the hose from the tank is plugged or the vent is not working.
___________________________

Let me know if this helps.

Joe
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Wednesday, March 31st, 2021 AT 6:12 PM
Tiny
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Are you sure this car has a fuel limiter vent valve on the tank? I can't find the part anywhere.
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Wednesday, March 31st, 2021 AT 7:29 PM
Tiny
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Hi,

That is what it shows in the manual. However, anything is possible.

Joe
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Wednesday, March 31st, 2021 AT 8:56 PM
Tiny
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Filled my tank today and gas entered normally. Temperatures here in AZ have risen to mid high 80's so could be heat that changed something, possibly loosened something that was sticking. We will see how it goes in the future.
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Tuesday, April 13th, 2021 AT 1:24 PM
Tiny
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Hi,

That's interesting. However, good to hear. I'm not sure what the heat would have done, but anything is possible.

Regardless, let me know if it gives you trouble again in the future. Also, please feel free to come back anytime in the future.

Take care,

Joe
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Tuesday, April 13th, 2021 AT 6:29 PM

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