E70 X5 Keep getting P0442 Small Evapor Leak

[gregg3gs]

The issue I had was with a code P0456 - EVAP System - Very Small Leak Detected, but to me it seems the same as yours.

Things I would notice while experiencing the issue:
- smell of gas inside the car
- smell of gas outside of the car, about the back of it (especially on hot days and after tank got to half +/- a 1/4 tank)

I was able to fix it.
My fix included:
- replacing the gas cap (I don't think it was the problem)
- replacing the seal, clamp, top retaining "C" assambly clamp on the fuel tank pump under the passenger rear seat (I don't think this was a problem)
- pulling fuel pump up and after disconnecting the connector noticing one of the pins had melted plastic around it. I filled the hole with JB Weld and connected the electrical connector to hold the assembly together until jb weld dried. Obviouse repair would be to replace the fuel pump. (this was the apparent problem)

All in all I understand that the original firmware in the x5 sends too much current to the fuel pump and it keeps connector hot, melting plastic around it. I had new firmware loaded a year after I got the x5 (car was five years old at that time), but the damage was already done.

I did the repair about two months ago, all is good now.