va997.2

Hi All,

Wanted to share my experience dealing with a P0455 EVAP code. Car is a C2S with just over 32k miles when it started throwing P0455: "Evaporative Emission System Leak Detected (large leak.)"

This code was intermittent at first, replaced the gas cap, but it would eventually return. When I started to notice a faint smell of gas, it was time to dive deeper.

Wound up smoking the EVAP system as follows:

• Pulled the battery and battery tray and immediately noticed the condition of the fuel pump flange (top most part of the tank into which the hoses and electrical connector attach), pictured here:

• All the discolorations turned out to be caused by cracks and holes in the flange. Here are some close ups.

• Pulled the charcoal canister and smoked the tank from the charcoal canister vent tube into the tank. Smoke billowed out all over the top of the flange. There was so much smoke, I could not identify the exact source, turns out it was from all of the little cracks and holes across the flange. Got a new flange, O-ring, and lock ring. Used the Schwaben tool (Schwaben Fuel Pump Lock Ring Tool) which worked out well. This last picture shows how to align the lock ring with the marker on the tank. C2 procedure, for the US model, is to torque the lock ring to 44 ft. lbs. then align the vertical line as shown below (vertical indented line on the ring lines up with the middle of the white plastic tab on the tank. Look for the circular hole in the lock ring, then down a bit to the left.)

• The P0455 has not returned, thankfully.

Update: The monitors are all in the Ready state (yay):

sven911t

Thanks for posting! This will no-doubt come in handy at some point.

Bruce In Philly

2009 C2S 191K miles

Wow, that is a real breakdown of material. I wonder why? Any ideas? Is it the environment? Where do you live? Did you have the vent line on the battery?

Thanx for posting, this will help others and maybe me at some point.

Peace
Bruce in Philly (now Atlanta)

va997.2

Thanks @sven911t.

@129183-bruce-in-philly, yeah although the "smoke show" was comical when troubleshooting, the underlying issue was both concerning and odd. Believe the deterioration is something that happened over a while, some kind of exposure that made the plastic crazy brittle. The vent hose was in place and the other side of the battery was plugged. However, the battery was newish, could have been a previous situation, where the plastic got compromised and just started cracking. I'm in the DC area, and the car has been a DC based car. Anyway, these things can happen, it seems fixed-fixed now, so I'm happy with that Thanks.