Need help with p0452 & p0440 codes

[99luminaguy]

Need some expert advice.
1999 chevy lumina car 3.8
fuel pump failed, had local garage install an Airtex unit for $200. I supplied the pump/sending unit.
Car ran fine post install for 5 months then started posting p0452 codes. Brought unit back and garage diagnosed as faulty fuel pressure sensor. Replaced sensor. Next day still posting p0452 codes. Brought car back and did another diagnostic and they said it needed charcoal canister vapor/valve. Another $300. later, the next day still posting p0452. Brought car back and the put my old charcoal canister back in and further diagnosed. Took pump/sending unit out and said some ball was stuck and needed to be freed up?? Put it back together but then started posting p0440 codes. They cleared it and then said I should drive the car and see what happens. Not only did the code come back but the next time I went to fill the tank, the car took 17.5 gallons and there was gas on the ground at the gas station. Looked like it was coming from the top of the tank not the fill neck area. Took car back to garage next day and they checked everything and could find no loose or bad hose connections. Took the car home and next day posted p0440 code. A few days later, yup took more gas than ever at the station, even went to a different pump, gas on the ground and now I'm pissed as you might imagine. I'm thinking of just taking it to the dealer and let them fix it since these local knuckleheads don't seem to know what they’re doing. I think the gas may be leaking out the o-ring on the sending unit since that was taken out the last go around. Any ideas or suggestions?

Frustrated 99luminaguy

By the way, the car has 189K miles and otherwise runs great!

[jhend82]

My 97 need a new fuel filler neck it has a pinhole in it that's throwing the p0440 code. Did you try replacing your gas cap too?

[99luminaguy]

Yes I had replaced the gas cap when the p0452 codes first started posted but no luck.

Here's an update. Since I could not bring myself to the idea of having to bring the car back for the 6th time to the local shop, my son and I decided to drop the tank yesterday and take a look. Yup, the o-ring was effed up (half way in place). This is where the gas was leaking from. ALSO we found the fuel level sensor was disconnected and hanging in place. It snaps into the side of the sending unit and they must have knocked it off when the removed the pump/sending unit the last go around. I didn't mention this in my last post but the fuel gauge was not reading correctly since the last repair attempt which now I know why…idiots!!! Anyway, put everything back together and went and filled the tank and no gas on the ground and it took 13.5 gallons which is in line with the vehicle history. Also the fuel gauge is now reading correctly. I cleared the codes and now we will see. I believe I resolved the p0440 as I have cycled now 6 times and no codes. Don't know if the p0452 will return, just have to wait and see. I sure am going to give these local knuckleheads a piece of my mind!!

[kevinb70]

congrats on finding a mechanic who blindly throws parts in your car at your cost.

[99luminaguy]

Good news, I resolved the p0440 by replacing the fuel pump o-ring, bad news is the p0452 has returned. Since I was able to recoup my last repair bill from the local garage ~$360., I decided to throw some parts at this problem at my expense. Since the fuel pressure sensor had already been replaced, I purchased a new vapor canister purge valve and purge solenoid. One installs in the driver rear wheel well on top of the vapor canister the other on the front of the engine next to the valve cover. Purchased both parts from Amazon for ~$35. (NICE!), but no luck, the p0452 posted returned on the third cycle.

Wondering if I have a leak somewhere, maybe in the fuel neck as it looks pretty corroded. I could purchase with a new one for ~$85., but now I’m guessing. I don’t have any other diagnostic capability other than a basic Actron unit to pull the codes, no monitoring capability. The code seems to return vary randomly, no observed pattern of any sort. I’m now wondering if I should take it to the dealer and let them diagnose or give it a shot with replacing the fuel neck? All the vacuum lines and connections to/from the pump to the purge solenoid look good. Barring a smoke test or more advanced diagnostic, no way of me pin pointing the problem. Anyone have any thoughts on this or should I just let the dealer diagnose further meaning $$$?

[jcmarkeson]

when you are at the gas station pumping look under for a leak, bring a white marker/paint pen and see if it's leaking, mine was but i am still throwing codes and i believe it is in the charcoal canister or canister purge solenoid but just am living with the stupid light.

[maxwedge]

my 98 was the filler neck rusted pin holes.

[mikedlox]

Originally Posted by maxwedge

my 98 was the filler neck rusted pin holes.

When you say yours was rusted pin holes in the filler neck what are you refering to? Was it leaking around the hose or where the metal meets the gas pump. Do your fix get the light to stay off? and what did you do to fix it thanks in advance for the reply

[maxwedge]

middle of the pipe had pin holes, very common issue here in rust country, new filler pipe fixed the issue and the cel.

[Bearwulf]

Originally Posted by 99luminaguy

Need some expert advice.
1999 chevy lumina car 3.8
fuel pump failed, had local garage install an Airtex unit for $200. I supplied the pump/sending unit.
Car ran fine post install for 5 months then started posting p0452 codes. Brought unit back and garage diagnosed as faulty fuel pressure sensor. Replaced sensor. Next day still posting p0452 codes. Brought car back and did another diagnostic and they said it needed charcoal canister vapor/valve. Another $300. later, the next day still posting p0452. Brought car back and the put my old charcoal canister back in and further diagnosed. Took pump/sending unit out and said some ball was stuck and needed to be freed up?? Put it back together but then started posting p0440 codes. They cleared it and then said I should drive the car and see what happens. Not only did the code come back but the next time I went to fill the tank, the car took 17.5 gallons and there was gas on the ground at the gas station. Looked like it was coming from the top of the tank not the fill neck area. Took car back to garage next day and they checked everything and could find no loose or bad hose connections. Took the car home and next day posted p0440 code. A few days later, yup took more gas than ever at the station, even went to a different pump, gas on the ground and now I'm pissed as you might imagine. I'm thinking of just taking it to the dealer and let them fix it since these local knuckleheads don't seem to know what they’re doing. I think the gas may be leaking out the o-ring on the sending unit since that was taken out the last go around. Any ideas or suggestions?



Frustrated 99luminaguy

By the way, the car has 189K miles and otherwise runs great!

As suggested, check fuel filter especialy if it was not replaced when new pump installed (should always install new filter). Run fuel pressure test after new filter. If still getting p0452 code check incoming signal wire for good connection @ both ends.