P0442 on 2011-2023 Dodge Charger: Causes and Fixes for an EVAP Small Leak

What's Unique About the 2011-2023 Dodge Charger

On the 2011-2023 Dodge Charger, P0442 issues are very frequently traced back to just two components: the gas cap and the EVAP purge valve. While EVAP systems are complex, owner experiences with this platform show these two parts fail more often than others. The other key component, the leak detection pump (ESIM), is consistently located in the rear passenger-side wheel well across this entire model year range, making it predictable to find if a smoke test leads you there. A video from "Know Your Parts" on YouTube demonstrates this exact location and replacement process on a Charger.

Generation note: The 2011-2023 Dodge Charger is the seventh (LD) generation. It received a major facelift for the 2015 model year, changing its exterior and interior styling. However, the fundamental EVAP system components and their locations, such as the purge valve and rear-mounted charcoal canister/leak detection pump, remain consistent across this year range. The platform is shared with the Dodge Challenger and Chrysler 300, which exhibit identical P0442 failure patterns.

Symptoms You May Notice

• Check Engine Light is on.
• A faint smell of fuel, particularly around the rear of the car (less common).
• Difficulty starting or a long cranking time immediately after refueling (this specifically points towards a faulty, stuck-open purge valve).
• Needing to clear the code repeatedly, only for it to return after a few weeks, is a common owner complaint.

Most Likely Causes

1. Loose, Worn, or Incorrect Gas Cap 🔴 High Probability → Shop Fuel Tank Cap The gas cap is a frequently used part, and its rubber O-ring seal naturally degrades over time from exposure to fuel vapors and weather, leading to a poor seal. Using a non-OEM, aftermarket cap is a very common trigger for this code, as they often don't seal correctly.
   How to confirm: First, ensure the cap is tightened until it clicks several times. Clear the code and drive for a few days. If the light returns, remove the cap and inspect the rubber seal for cracks, stiffness, or damage. A cracked o-ring is a definitive sign the cap is bad.
   Typical fix: Replace the gas cap with a new, OEM (Mopar) part to ensure a perfect seal. This is the cheapest and easiest first step. 🎬 Watch: Step-by-step guide to fixing P0442 with a gas cap.
   Est. part cost: $20-$35
2. Faulty EVAP Purge Valve / Solenoid 🟡 Medium Probability → Shop Vapor Canister The purge valve is an electromechanical part that cycles frequently. Over time, it can weaken and fail to close completely, creating a small, permanent leak in the system. This is a common failure point on many Chrysler/Dodge vehicles and their platform mates.
   How to confirm: The valve is typically located in the engine bay, on top of the engine. A key symptom is a long crank after refueling. To test it, disconnect the valve and try to blow through it; if air passes, it's stuck open and faulty. A mechanic can also command it open and closed with a scan tool to check its function.
   Typical fix: Replace the purge valve. It is usually held by one or two bolts and has two hoses and an electrical connector, making it a straightforward DIY job. 🎬 See this walkthrough for replacing the 5.7 Hemi purge valve.
   Est. part cost: $25-$60
3. Cracked or Disconnected EVAP Hoses 🟡 Medium Probability
   How to confirm: Visually inspect all accessible EVAP lines running from the engine bay to the rear of the vehicle for any obvious cracks, brittleness, or loose connections. The definitive method is to have a mechanic perform a smoke test, which forces smoke through the EVAP system and makes even the smallest leak visible. 🎬 Watch: How to find a small EVAP leak using smoke. Smoke will be seen escaping from the point of the leak.
   Typical fix: Replace the cracked section of hose or the entire hose assembly if the damage is extensive. Ensure all connections are secure.
   Est. part cost: $10-$60
4. Faulty Leak Detection Pump (ESIM) or Seal ⚪ Low Probability → Shop Evaporative Emissions System Leak Detection Pump This component, also called an Evaporative System Integrity Monitor (ESIM), is located in the rear passenger wheel well area, often on top of the charcoal canister. The internal diaphragm can fail, or the O-ring that seals it to the canister can dry out and crack, causing a leak. The seal itself is a common failure point.
   How to confirm: This is typically found with a smoke test, where smoke will be seen escaping from the pump housing or its seal. Access requires removing the rear passenger wheel and fender liner. A YouTube video by user "boosted Scat" shows the replacement process on a 2013 Charger.
   Typical fix: Replace the leak detection pump module and its sealing O-ring. This requires removing the rear passenger wheel and fender liner for access. It is critical to install the new ESIM in the correct orientation as it contains weighted switches.
   Est. part cost: $30-$70

Rare But Worth Checking

• Cracked Charcoal Canister: → Shop Vapor Canister The plastic body of the charcoal canister itself can develop hairline cracks from road debris impact or age, creating a leak. This is usually found during a smoke test.
• Cracked Fuel Filler Neck: → Shop Fuel Filler Neck The pipe leading from the gas cap to the fuel tank can rust or crack, causing an EVAP leak. This is more common in regions with heavy road salt use and can sometimes cause a visible fuel leak when refueling.

Diagnosis Steps

1. Check the Gas Cap: Remove and reinstall the gas cap, ensuring it clicks multiple times. Clear the code. If it returns, inspect the cap's rubber seal for damage and replace it with an OEM Mopar part if it looks worn.
2. Visual Inspection: Carefully inspect all visible EVAP hoses and lines in the engine bay and under the car. Look for any signs of cracking, brittleness, or loose connections, especially at connection points.
3. Test the Purge Valve: Locate the purge valve in the engine bay. Disconnect it and attempt to blow through it. If air passes, the valve is stuck open and must be replaced. A stuck-open purge valve can also cause difficulty starting after refueling.
4. Perform a Smoke Test: If the previous steps do not reveal the cause, the most effective next step is a smoke test. A machine is used to fill the EVAP system with a harmless, visible smoke. The leak will be identified by where the smoke escapes. Pay close attention to the leak detection pump (ESIM) area in the rear passenger wheel well, the fuel filler neck, and all hose connections during this test.
5. Inspect Components Identified by Smoke Test: Once the smoke reveals the leak's location (e.g., a hose, the charcoal canister, or the ESIM pump), replace the faulty component.

Parts You'll Likely Need

• Fuel Cap (OEM #52129436AF (example, verify for specific year)) — This is the most common cause of a P0442 code due to its seal wearing out over time. Always use an OEM Mopar cap for best results.
  Trusted brands: Mopar
  OEM price range: $20-$35
  Aftermarket price range: $10-$25
• EVAP Purge Valve / Solenoid (OEM #4627694AB (V6/V8, 2015+), 04891741AA (V6/V8, ~2011-2017), 4891738AD (V6, ~2016-2019)) — This valve frequently gets stuck partially open, causing a persistent small leak. Part numbers vary by engine and year.
  Trusted brands: Mopar, Bosch, Standard Motor Products, Autopart Premium
  OEM price range: $40-$60
  Aftermarket price range: $25-$50
• EVAP Leak Detection Pump (ESIM) (OEM #04862314AD (example, verify for specific year)) — The seal on this pump can fail, or the pump itself can malfunction, creating a leak. It's a common failure point found during a smoke test.
  Trusted brands: Mopar, Dorman
  OEM price range: $50-$80
  Aftermarket price range: $30-$70
• ESIM to Canister Seal / O-Ring (OEM #52129436AB) — Often, only the rubber O-ring that seals the ESIM to the charcoal canister fails. This is a cheap part that can solve the leak without replacing the entire ESIM pump.
  Trusted brands: Mopar
  OEM price range: $5-$15
  Aftermarket price range: $5-$10

Related Codes That Often Appear With This One

• P0456 — P0456 indicates a 'very small leak.' You might see this code along with P0442 if the leak is on the borderline between the two detection thresholds.
• P0455 — P0455 indicates a 'large leak.' If a small leak from a cracked hose or failing seal suddenly gets worse, it can trigger a P0455 code.

Technical Service Bulletins (TSBs) & Recalls

• UB4 - Emissions Recall for Evaporative Emissions Canister on 2015-2016 models.

Platform-Specific Known Issues

• Emissions Recall UB4 was issued for 2015-2016 Dodge Chargers because the evaporative emissions canister might not absorb enough fuel vapors, but this typically sets other codes, not P0442.

Mechanic-Grade Diagnostic Values

• Fuel Tank Pressure (FTP) Sensor Voltage — expected: Approximately 1.5 Volts with the system at atmospheric pressure (engine running, system vented).. Failure: A reading that does not change when the EVAP system is sealed and a vacuum is applied via a scan tool command may indicate a faulty sensor or a significant leak.

Scan Tool Commands That Help

• wiTECH (Chrysler/Dodge/Jeep OEM tool) or equivalent advanced scanner: EVAP System Test / Purge/Seal Test — This function is used to command the EVAP vent valve closed and the purge valve open, applying engine vacuum to the entire system. The scan tool then monitors the Fuel Tank Pressure (FTP) sensor to see if the system holds the vacuum. A rapid loss of vacuum confirms a leak is present without needing a smoke machine for initial verification.
• wiTECH or equivalent advanced scanner: Vent Valve Control — During a smoke test, the vent valve is normally open. This command allows the technician to close the vent valve electronically, sealing the system so the smoke machine can build pressure and reveal leaks. This is critical for accurately performing a smoke test.

Wiring & Ground Locations

• G300 — Below the left (driver's side) 'B' pillar.. While not directly part of the EVAP circuit, poor chassis grounds can cause erratic behavior in various electronic modules and sensors. Ensuring the main body grounds like G300 are clean and secure is a good practice if electrical issues are suspected with EVAP components.
• Battery Negative to Chassis Ground — The main battery is in the trunk, next to the spare tire. There is a primary ground connection there. An auxiliary negative terminal post for jumping is located in the engine bay.. The entire EVAP system relies on a stable ground reference. The purge solenoid and ESIM pump are controlled by the PCM, which needs a solid ground to function correctly. A poor main ground could theoretically cause intermittent faults in these components.

Real Owner Repair Stories

• Forum user on ChargerForums (Not specified, but within the 2011-2023 generation) — Persistent P0442 code.
  ❌ Tried (didn't work) Replaced gas cap, Replaced purge valve
  ✅ What actually fixed it After a smoke test, a small, hard-to-see crack was found in a hose right at the charcoal canister connection. The hose looked fine on visual inspection but leaked under pressure.
• Dodge Owner Complaint — An owner reported taking their vehicle to the dealer three times for the same P0442 error code, where the dealer replaced several emission parts to resolve the issue (NHTSA ODI #746191).

"I Checked Everything" — The Actual Cause

• In a documented case on a similar Dodge vehicle, a smoke test showed no leaks with the wiring harness connected to the leak detection pump (ESIM). However, when the electrical connector was disconnected from the pump, smoke began pouring out of the connector itself, indicating an internal failure of the pump was allowing vapor to pass through the electrical pins.

OEM Part Supersession History

• 4891741AA → 4891741AC — Part revision and update by the manufacturer. The -AC version is the current replacement for the -AA.
  Heads up: The 4891741AC is the correct universal replacement for 4891741AA. Using a visually similar part with a different number could lead to incorrect spring tension and continued failure.

Model Year Variations Within This Range

• 2007-2023: While the location of the charcoal canister and leak detection pump (ESIM) remains in the passenger rear wheel well, the physical shape of the canister and the style of the ESIM pump may differ. Earlier models (pre-2011) may have a different style pump, but models from 2011-2023 generally use a similar square-box style ESIM, even if the canister itself varies in shape (boxy vs. cylindrical).

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

• P0456 — EVAP System Small Leak (0.020") - Very closely related to P0442, sharing the exact same root causes such as a degraded gas cap O-ring, faulty ESIM seal, or cracked EVAP hoses.
• P0455 — EVAP System Large Leak - Can be triggered instead of P0442 if the gas cap is completely left off or if an EVAP hose is completely disconnected rather than just cracked.
• P0441 — EVAP System Incorrect Purge Flow - Directly related to the faulty or stuck-open EVAP purge valve mentioned as a common cause for the Charger's long crank times.
• P0457 — EVAP System Leak Detected (Fuel Cap Loose/Off) - Specifically points to the gas cap, which is the most common high-probability cause for EVAP leaks on this platform.

Frequently Asked Questions