Malibu L4-2.2L VIN F (2005)
Chevrolet Malibu, DTC P0442 or P0455 may be set by either a cracked EVAP canister or a fuel gauge that does not measure fuel level accurately. For
EVAP canister concerns, refer to bulletin 05-06-04-004A. For fuel gauge concerns, refer to bulletin 04-08-49-025.
If the fuel cap cannot be tightened or removed, proceed to the section below titled, Replacing Broken Fuel Cap.
If DTC P0442 - Evaporative Emission (EVAP) System Small Leak Detected is stored in the Engine Control Module (ECM), proceed to section titled
DTC P0442.
If DTC P0455 - Evaporative Emission (EVAP) System Large Leak Detected is stored in the ECM, proceed to section titled DTC P0455.
Refer to the appropriate Service Information (SI) for additional Diagnostic Assistance.
Some vehicles may intermittently set a DTC of P0442 or P0455, leak in the evaporative emissions system. In addition to checking the system and
performing the diagnostics as described in the Service Information for this DTC, the technician should be aware that some of the fuel caps used on GM
vehicles may not seal adequately to the filler neck if pushed down when being tightened. This may occur more often when this cap is used on a vehicle
with a steel fuel filler neck. The owner should be instructed not to apply a downward force to the fuel cap when tightening.
Replacing Broken Fuel Cap
Remove the fuel cap tether from the fuel filler pocket or fuel filler door.
Remove the fuel cap from the fuel filler.
If the fuel cap cannot be removed, remove the fuel cap ratcheting cover by releasing the four (4) tabs holding the cap cover to the lugged sealing base.
Position the radiator hose removal tool or similar type tool between the black cover and white inside body, and pry the cover over the retaining tab by
rotating the tool counter clockwise. Repeat, if necessary, on the 3 other locations around the cover.
Remove the white fuel cap base from the filler pipe by rotating the fuel cap base counter clockwise.
Install the new fuel filler cap and secure the tether to the fuel filler pocket or filler door.
DTC P0455 - (Evaporative Emission (EVAP) System Large Leak Detected)
Diagnostic Aids: P0455 diagnostics is checking for a large leak in the EVAP system. Examples of conditions that may contribute to this code setting are:
loose or broken fuel cap, disconnected or cracked EVAP lines, cracked charcoal canister, sticking purge or vent solenoids, inaccurate fuel gauge, etc.
DTC P0442 - (Evaporative Emission (EVAP) System Small Leak Detected)
Diagnostic Aids: P0442 diagnostics is checking for a 0.5 mm (0.020 in) sized hole in the EVAP system. Examples of conditions which may cause this
type leak could include: cracked EVAP lines, cracked charcoal canister, a cut or dirty fuel cap seal, debris on the purge or vent solenoid internal seals,
loose fuel lines, etc.
Refer to Fuel Cap Inspection for P0442.
Fuel Cap Inspection for P0442
