P0442 on 2002-2006 Honda CR-V: EVAP Small Leak Causes and Fixes

What's Unique About the 2002-2006 Honda CR-V

On the second-generation Honda CR-V, the EVAP system components are generally robust, but like many vehicles of this era, the most common failure points are simple seals and valves. The gas cap is the number one culprit, often due to a worn-out rubber seal. If the cap isn't the issue, the system's various rubber hoses and valves are the next logical places to look for age-related cracks or failures before suspecting more expensive components like the charcoal canister. The fuel filler neck is also a known weak point for rust in salt-belt regions, which can prevent a good seal.

Symptoms You May Notice

• Check Engine Light is on.
• A faint fuel smell may be noticeable, especially when parked in an enclosed space like a garage (this is less common).
• No noticeable impact on vehicle performance or drivability in most cases.
• Difficulty starting or a long crank time immediately after refueling, which can point to a stuck-open EVAP purge valve.

Most Likely Causes

1. Loose, Damaged, or Incorrect Gas Cap 🔴 High Probability The rubber O-ring on the gas cap can dry out, crack, or become compressed over time, preventing a proper seal. Aftermarket caps are a frequent cause of this code as they may not meet Honda's specific sealing requirements.
   How to confirm: First, ensure the cap is tightened until it clicks at least three times. Inspect the rubber seal for any cracks, stiffness, or damage. Check the metal filler neck for any rust or debris that could prevent a good seal.
   Typical fix: If the cap is loose, tighten it, clear the code, and drive for a few days. If the seal is damaged or you have an aftermarket cap, replace it with a new OEM Honda part (17670-SJA-013 or 17670-S5A-A32).
   Est. part cost: $25-$50
2. Cracked or Disconnected EVAP Hoses 🟡 Medium Probability The rubber and plastic hoses that make up the EVAP system become brittle with age and exposure to engine heat and the elements. Small cracks, especially at connection points and bends, are common.
   How to confirm: Visually trace the EVAP lines from the engine bay (near the intake manifold) to the charcoal canister at the rear of the vehicle. Look for any obvious cracks, splits, or loose connections. A smoke test is the most effective way to find a leak that isn't visually apparent.
   Typical fix: Replace the cracked section of hose or the faulty connector. Small rubber vacuum lines can be purchased by the foot, while larger molded hoses are part-specific.
   Est. part cost: $10-$60
3. Faulty EVAP Canister Purge Valve ⚪ Low Probability
   How to confirm: The purge valve is located in the engine compartment and is normally closed. A simple DIY test is to disconnect the hose coming from the canister, start the engine, and disconnect the valve's electrical connector. Place a wet finger over the valve's inlet port; if you feel any vacuum, the valve is stuck open and faulty. A professional can also command it open and closed with a scan tool to verify its operation.
   Typical fix: If the valve is stuck open or does not seal properly, it must be replaced. The OEM part number is often 36162-PNA-003.
   Est. part cost: $50-$150
4. Faulty EVAP Vent Solenoid / Canister Close Valve (CVS) ⚪ Low Probability
   How to confirm: This valve is located near the charcoal canister at the rear of the vehicle, typically on the driver's side. It is normally open and closes when the ECM runs its leak test. It can get stuck open due to dirt or internal failure. Diagnosis typically requires a scan tool to command the valve shut and a smoke machine to see if it leaks.
   Typical fix: Replacement of the vent solenoid assembly. It can sometimes be cleaned, but replacement is often necessary.
   Est. part cost: $70-$180

Rare But Worth Checking

• Cracked EVAP Charcoal Canister: While less common for a small leak, the plastic housing of the canister can develop fine cracks over time. This is more likely if the vehicle has been in a rear-end collision or if the canister was damaged during service. Overfilling the fuel tank can also saturate the canister with raw fuel, leading to damage.
• Rusted Fuel Filler Neck: In regions where road salt is used, the metal fuel filler neck can rust where the gas cap seals, creating an uneven surface that prevents a proper seal even with a new cap. This is a well-documented issue on the CR-V and its platform mate, the Honda Element. Some owners use a wire brush to clean the surface or apply a thin layer of silicone grease as a temporary fix.

Diagnosis Steps

1. Read the code with an OBD-II scanner to confirm P0442 is present. Note any other codes.
2. Inspect the gas cap. Remove it, check the seal for cracks, and ensure it's an OEM part. Clean the filler neck sealing surface. A wire brush can be used on a rusted filler neck, followed by a light coat of silicone grease to help seal.
3. Tighten the gas cap until it clicks at least 3 times. Clear the code with the scanner.
4. Drive the vehicle for a few days to see if the Check Engine Light returns. This allows the EVAP monitor to run its self-test.
5. If the light returns, perform a thorough visual inspection of all accessible EVAP hoses and lines in the engine bay and under the vehicle, leading to the charcoal canister.
6. If no visual faults are found, the most effective next step is to have a professional perform a smoke test. This involves injecting pressurized smoke into the EVAP system to quickly and accurately reveal the location of any leaks.
7. If a stuck purge valve is suspected (e.g., long crank after refueling), perform the DIY finger vacuum test described in the 'Common Causes' section.
8. Based on the test results, replace the faulty component (e.g., hose, purge valve, vent solenoid, or canister).
9. After the repair, clear the code and perform a drive cycle to confirm the fix.

Parts You'll Likely Need

• Fuel Filler Cap (OEM #17670-SJA-013 (common replacement) or 17670-S5A-A32 (original for 02-04)) — This is the most frequent cause of a P0442 code due to a worn or cracked seal. Using an OEM cap is highly recommended as aftermarket versions often fail to seal correctly.
  Trusted brands: Honda (Genuine OEM)
  OEM price range: $25-$50
  Aftermarket price range: $15-$30
• Canister Purge Valve Solenoid (OEM #36162-PNA-003) — This valve in the engine bay can stick open, causing a persistent small leak. This part number is shared with other Hondas/Acuras of the era, like the Civic and RSX.
  Trusted brands: Honda (Genuine OEM), Denso, Standard Motor Products
  OEM price range: $80-$150
  Aftermarket price range: $40-$90
• EVAP Canister Assembly (OEM #17011-S9A-A00) — If the canister itself is cracked or its integrated valves have failed, the entire assembly may need replacement. This part number is cited for 2005-2006 models.
  Trusted brands: Honda (Genuine OEM), Dorman
  OEM price range: $290-$415
  Aftermarket price range: $205-$250

Related Codes That Often Appear With This One

• P0455 — A P0455 (Gross EVAP Leak) might appear if a small leak worsens over time. A component that was causing a small leak could fail completely.
• P0456 — A P0456 (Very Small EVAP Leak) is a similar code for an even smaller leak. Sometimes the computer's leak detection threshold can fluctuate, causing either code to appear for the same root cause.
• P0457 — This code specifically means 'EVAP Leak Detected (Fuel Cap Loose/Off)'. If you see this with a P0442, it strongly points to the gas cap or filler neck as the source of the problem.

Platform-Specific Known Issues

• Fuel Filler Neck Corrosion: Owners in areas with road salt report significant rust on the fuel filler neck where the gas cap seals. This prevents even a new cap from sealing properly. A user on honda-tech.com with P0442 and P0457 codes replaced the cap and cleaned the filler neck, but the issue persisted until the tank was kept nearly full, suggesting a leak that is sensitive to fuel level. Cleaning the surface with a wire brush or replacing the entire filler neck (a job shared with the Honda Element) may be required.

Mechanic-Grade Diagnostic Values

• EVAP Canister Purge Valve Solenoid Resistance — expected: 15 to 30 Ohms. Failure: A reading outside this range (e.g., open circuit or short) indicates a faulty solenoid coil.
• EVAP Canister Vent Solenoid (CVS) Resistance — expected: 20 to 30 Ohms. Failure: A resistance measurement outside of this specified range points to a damaged solenoid winding.
• Mode $06, Test ID $91, Component ID $80 — expected: The measured value, representing fuel tank pressure change, must be below a maximum threshold set by the manufacturer.. Failure: A value that exceeds the programmed limit indicates a failure of the small leak test, triggering code P0442.

Hidden / Shadow Codes Worth Checking

• Test ID $91 / Comp ID $80: This is not a separate trouble code but a specific monitor within OBD-II Mode $06. It represents the result of the onboard diagnostic test for a small (0.040") EVAP system leak. A 'fail' result for this test is what triggers the P0442 DTC. (see via A professional scan tool or an advanced consumer OBD-II scanner with Mode $06 capability is required to view these test results.)

Scan Tool Commands That Help

• Honda HDS (or equivalent professional scanner): EVAP System Test Function (includes Vent Valve Control) — This bidirectional command is used to manually close the normally-open EVAP Vent Solenoid. Sealing the system is a required first step before performing a smoke test or a pressure/vacuum decay test to find the physical source of a leak.

Wiring & Ground Locations

• G101 — On the left side of the engine/engine compartment.. This is a primary engine and chassis ground. Corrosion or a loose connection at G101 can cause intermittent or incorrect operation of various engine sensors and solenoids, including the EVAP purge valve, leading to spurious codes.
• G301 — Behind the left side of the front bumper.. This ground point serves components in the front of the vehicle. While less directly tied to the EVAP system than G101, poor grounding here can contribute to electrical noise and unpredictable behavior in the vehicle's electrical system.
• EVAP Canister Purge Valve Connector — On top of or near the throttle body/intake manifold in the engine bay.. This is the electrical connection for the purge valve. Technicians test for voltage and ground at this connector's pins to determine if a failure is in the valve itself or the wiring from the ECM.

"I Checked Everything" — The Actual Cause

• For 2002-2004 models, a faulty Fuel Tank Pressure (FTP) sensor can be the root cause of an EVAP code even if a smoke test passes. Honda issued TSB 06-073 for this issue, where the sensor fails internally and sends incorrect pressure readings to the ECM, simulating a leak when none exists. Because there is no physical leak, a smoke test will come back clean, leading technicians to overlook the sensor itself as the culprit.

When the Usual Fixes Don't Work

• While the vast majority of P0442 codes are caused by physical leaks (from the gas cap, hoses, or valves) that a smoke test can find, a notable exception on the 2002-2004 CR-V is an electrical failure of the Fuel Tank Pressure (FTP) sensor. As detailed in Honda TSB 06-073, the sensor can fail internally and report a pressure drop to the computer even when the system is perfectly sealed. In this scenario, a technician who relies solely on a smoke test after checking the gas cap will be unable to find the fault, as no smoke will escape. The true cause is not a leak, but a faulty sensor tricking the ECM into thinking a leak exists.

OEM Part Supersession History

• 17670-S5A-A31 → 17670-S5A-A32 — Standard part revision and update by the manufacturer.
  Heads up: The new part number (17670-S5A-A32) is the correct replacement for the original and is specified for 2002-2004 CR-V models.

Model Year Variations Within This Range

• 2002-2004 vs. 2005-2006: The EVAP charcoal canister assembly and its associated components are different between the pre-facelift (02-04) and facelift (05-06) models. A video guide for a 2005-2006 model replacement notes the specific design for those years. Additionally, a Technical Service Bulletin (TSB 06-073) for a faulty Fuel Tank Pressure sensor specifically applies only to 2002-2004 models, indicating a change in that part or system for 2005.

Diagnostic Flowchart

Real Owner Stories

Aggregated from forums and TSBs cited above. Mileages and costs reflect what owners reported in those sources.

Related OBD-II Codes

• P0457 — EVAP Emission System Leak Detected (gas cap loose/off). Frequently appears alongside P0442 on the CR-V due to a loose gas cap or corroded fuel filler neck.
• P0420 — Catalyst System Efficiency Below Threshold. Mentioned in owner reports as appearing concurrently with P0442 and P0457 on higher-mileage CR-Vs.
• P0455 — EVAP System Leak Detected (Large Leak). Shares the exact same root causes as P0442, such as a completely missing gas cap, severely cracked EVAP hoses, or a stuck-open purge valve.
• P0456 — EVAP System Leak Detected (Very Small Leak). Caused by the same failing components as P0442, such as a degrading gas cap O-ring or minor fuel filler neck corrosion, just detected at a smaller leak threshold.
• P0441 — EVAP System Incorrect Purge Flow. Can be triggered by the same faulty EVAP Canister Purge Valve (OEM 36162-PNA-003) that causes P0442.

Frequently Asked Questions