P0442 on a 2011 Ford Fusion Hybrid

P0442 means the EVAP system could not hold pressure or vacuum during a leak test, but the leak is small.

Not your vehicle? See general P0442 info.

Most common causes on the 2011 Ford Fusion Hybrid

Ranked from 2,869 NHTSA owner complaints filed for this vehicle.

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1
Cracked fuel tank at the top seam (purge-valve pressure-spike pattern)
High severity
A large cluster of owners on this exact vehicle report a cracked fuel tank/fuel odor/leaking fuel, matching the documented Ford recall tying tank cracking to canister purge valve pressure spikes.
Reported in 8 NHTSA complaints
Parts:fuel tank
2
Failed or stuck canister purge valve
High severity
Several complaints explicitly identify the canister purge valve as failed, which can also be the root cause behind the tank-cracking pattern on this vehicle.
Reported in 5 NHTSA complaints
Parts:purge valve
3
Charcoal canister fault
Medium severity
Owners report vapor backing up into the fill tube and canister-related fault codes alongside the tank/purge issues.
Reported in 3 NHTSA complaints
Parts:charcoal canister
4
Faulty capless fuel-fill inlet door/seal
Medium severity
Owners report the 'check fuel fill inlet' light staying on, indicating the capless filler door isn't sealing properly and creating a small EVAP leak.
Reported in 2 NHTSA complaints
5
Loose or worn gas cap/filler seal
Low severity
Standard small-leak cause on non-capless trims; check cap seating and O-ring condition first.
Common cause
6
Cracked or aged EVAP vent hose
Medium severity
Heat-cycled rubber lines in the EVAP system develop small cracks that fail the leak-detection test.
Common cause

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These causes are aggregated from NHTSA owner complaints and general repair knowledge — this is not a diagnosis. P0442 on your car still needs shop confirmation before any repair.

Common symptoms

Check engine light
Fuel smell near vehicle
Usually drives normally
Hard start after fueling in some cases

What to check before replacing parts

Tighten and inspect the gas cap

Look for: A cap that doesn't click to full tightness, has a visibly cracked or flattened seal, or is simply missing is the single most common cause of a small EVAP leak — rule it out first.

Smoke-test the EVAP system

Look for: Because this is a small leak, expect only a thin wisp of smoke or a faint hiss at one spot (a hose, seam, or valve) rather than an obvious cloud — look closely and take your time.

Check purge valve sealing

Look for: A purge valve that doesn't hold vacuum when commanded closed lets a small amount of air bleed through, which the system reads as a leak during its self-test.

Inspect hoses near the tank and engine bay

Look for: Look for small cracks, soft/collapsed spots, or a hose that has pulled loose slightly at a fitting — any of these can leak just enough to trip a small-leak code without an obvious fuel smell.

Verify vent valve operation

Look for: A vent valve that doesn't seal fully when commanded closed prevents the system from holding vacuum during its self-test, which reads as a small leak even with no physical leak in the hoses.

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Matching symptoms

Check Engine Light