E70 X5 Keep getting P0442 Small Evapor Leak

[imalabil]

Mine is going in on Tuesday and the light came on this morning. I'll let you know what they find.

[ard]

Originally Posted by wetzie

I
Looking for the next step or taking it to the dealer. MD has the worthless emissions inspection and will need to get this resolved so I can pass inspection and stop paying penalties.

I dunno...DOES keep people from driving around ignoring emissions issues!

I assume you have the evap hose diagram and have checked every single component??? not just hoses, but valves, fittings, even the tank?

[gregg3gs]

Originally Posted by wetzie

It would be great to follow this through to a fix. I am having the same code P0442 and is keeping the CEL on. The 2009 X5 3.0 is out of warranty and is sitting at 56K miles. It runs very well with no smells or hesitation. I purchased the BMWhat ap and reset the CEL and the X5 would run with no errors for several days. It starts with the check gas cap error and then later puts up the CEL a couple of days later.
I purchased a new gas cap and the problem came back quickly.
I then purchased a DMTL pump and did the replacement procedure posted from Gregg3gs.
Visually inspected the hoses and checked the connections at the wheel well side.
Looking for the next step or taking it to the dealer. MD has the worthless emissions inspection and will need to get this resolved so I can pass inspection and stop paying penalties.

wetzie - notice I updated the diy. I found my electrical connector melted, therefore the vapors were leaking out of the tank and generating the error.

[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.

[regdfry]

X5Cat,

Looks like you have hepled expose a potentially explosive situation, with those photos and your description!

I think BMW is on warning (yes, they read these forums) that there are X5's rolling around that have a serious safety problem!

Who knows when the conditions will be just right for one of these afflicted X5's to become an explosive burning hulk of high tech metals, plastics, glass and leather comfort seats?

[X5Cat]

Yes, I am thinking this could be potential safety recall material. I think anyone with one of these vehicles should be inspecting for the same problem, or have a shop check it out carefully.

[regdfry]

Examples of X5 fires: http://www.xoutpost.com/bmw-sav-foru...highlight=fire

See posts #1 and #11 for visual evidence of X5's that have had experience with fire.

[gregg3gs]

Originally Posted by X5Cat

Yes, I am thinking this could be potential safety recall material. I think anyone with one of these vehicles should be inspecting for the same problem, or have a shop check it out carefully.

Guys, I don't think this is just one truck with this problem.
I know of many fuel pumps being replaced by indy shops, and it was my mechanic who led me to look in this direction.

I'm sure BMW reads these posts but something makes me wonder if they would care to fix this issue (I wonder hos explosive is the situation?)

The new fuel pump can be got for @121.64 at BMW of South Altanta Online
Fuel pump and fuel level sensor. Fits: 2008 BMW X Series (E53,E70,E71,E83) X5 4.8i | BMW of South Atlanta

I believe the part is over $300.00 if you were to walk into your local dealer (I called one when my failed)

[gregg3gs]

Originally Posted by regdfry

Examples of X5 fires: http://www.xoutpost.com/bmw-sav-foru...highlight=fire

See posts #1 and #11 for visual evidence of X5's that have had experience with fire.

Yeah, that was nice roasting.

[X5Cat]

Thanks, gregg3g. But I fear that may be the wrong part. Best I can tell for my 3.0, to get assembly with new pump and plastic "lid", is $264. Part No. 16117195463. Found it on Ebay for $244 w/ free shipping, although from NJ. I want new pump included just in case there is any problem with worn pump drawing more current, although I don't feel that is the primary issue. I think main issue is just some sort of weakness in the electrical connection at that pin. Corrosion or maybe just loose fit, possibly even reaction between different metal types, who knows. The current found the weakest link and overheated it. I need to find a new pigtail connector, as I want to start out with an all-new connection.