E70 X5 Keep getting P0442 Small Evapor Leak

[X5Cat]

Originally Posted by gregg3gs

- pulling fuel pump up and after disconnecting the connector noticing one of the pins had melted plastic around it.

You nailed it, gregg3gs! Finally pulled up the rear seat yesterday afternoon. Smelled a hint of fuel as soon as I lifted the seat up. Then, as I unbolted and lifted up the round metal access plate above the fuel pump, a strong fuel smell. Unsnapped the electrical connectors and discovered a charred wire (the wire closest to the right side of the vehicle). The corresponding electrical pin on the fuel pump seems to be fused to the pigtail connector. The pin and fuel pump wire lead pulled out, still attached to the pigtail, revealing a hole in the plastic top of the fuel pump where the pin was supposed to be imbedded. You can see the fuel in the tank, through the hole. The pump wire lead is charred to the point that the red insulation is black, and it crumbles when touched. Looking closely, I could see that the pigtail connector itself had been overheating and melting. I saw some sort of amber colored gel down in there that makes me wonder if someone had attempted some sort of repair before. Now I have to decide whether I want to try a repair myself or just replace the whole pump and the pigtail. I have attached photos. I will also follow up with whatever type of fix I decide to pursue.