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Discussion Starter · #1 · (Edited)
Annoying P0442 Code (small EVAP leak) on 2002 Fronty

Hello all. I have a 2002 Nissan Frontier with the 2.4L and manual transmission. I've been dealing with this P0442 code for quite a while. Sometime early last year, I got sick of it and started replacing all the parts. I put new hoses, replaced the charcoal canister, vacuum cut valve, EVAP canister valve, and pretty much everything else. Unfortunately, the code kept coming back. Turned out to be the gas tank/fuel pump-sending unit area had rusted out. I fixed that and then the code was off for over a year. About a week or so ago, the code came back. I went through with a spray bottle with soapy water and tried finding another leak. I tried the top of the tank again and didn't have any luck with leaks. I tried cleaning the vent valve on the charcoal canister but that didn't fix it either.

Any ideas on what direction to go now? I might just try to find an OEM gas cap and try that. I have a newish Stant cap on it now.
 

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Discussion Starter · #3 ·
Did some more testing today. It turned out to be the gas tank seal again. I'm thinking since I had to remove a lot of rust from the tank the first time around, maybe the regular tank seal wasn't doing the trick. So, I'm going to order a thicker tank seal and see how that does.
 
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