I have just bought a 2009 base corvette and really got a great deal on it, but it does have the dreaded gas smell when filled over half way and has a check engine light throwing an emissions code P0442. I knew this was going to be an issue but I bought the car for $9500 and it has detailed service records totaling $9,800 in 2024. This issue does not bother me a ton, but my wife telling me the garage smells like gas twice a day is driving me insane so I might as well go ahead and knock it out.

First question, am I correct in thinking that this has to be the fuel pump issue where the plastic cracks? And if so, what all should I be looking to replace when I drop the tank? I have saw mentions of the pump and the crossover tube but am not 100% sure! I will be doing this repair with a Subaru technician so he has all of the mechanical knowledge but maybe not a good idea of what the process looks like, so any links or videos for that would also be awesome!

Part numbers, names, and links are GREATLY appreciated!

Thank you!

 

Be VERY careful some parts are no longer available new from GM. I suggest replacing the pump assembly in the drivers tank and the level sender in the passengers tank. Yes there are 2 tanks. If you have the manual transmission you can do it without removing the transmission. If you have the automatic you'll need to remove the transmission. If you have a lift and transmission jack and supports it may be easier to drop the entire torque tube and rear end as an assembly.

 

The parts are showing discontinued from GM but Rockauto has them.

DRIVERS SIDE PUMP ASSY - 19420860
PASSENGERS SIDE LEVEL SENDER - 19420830

 

I should have added that it is an automatic! I will be doing the repairs at the Subaru dealership I work at so will definitely have a plethora of tools to knock it out!

Thank you for part numbers! Should I also look into replacing the crossover tube? I had saw mentions of it but in my scanning online I am unsure of what exactly it is so I am unsure of what to order!

 

I could be wrong but I don't think the crossover tube was sold as an assembly. The connector pipe (crossover) is part # 19436041 and shows discontinued. I don't see it on rockauto. The rear auxiliary feed and return pipe looks like it goes thru the connector pipe and I belive is Included (that's how it looks on the parts diagram) #10337588 also discontinued. That's why I said be super careful.

 

Plenty of YouTube vids on the job being done. You don't necessarily have to pull the auto trans to get to it. Many have done without. I read a thread somewhere about a way to do it that I may do if the smell starts on my 07. Remove the motor mounts and intake manifold (so as to not hit firewall) so entire driveline can tilt down after rear end unbolted.

The crossover tube I got is 15223882 Fuel Feed hose. Usually the reason it gets replaced is because it is stainless accordion type pipe that gets stiff over the years and hard to compress to remove and reinstall.

Expect the Auxiliary feed lines, in each tank that go from pump to crossover tube, to break at the connection. The part that attaches it to the tank needs to be secure and not shift as you are trying to poke the crossover tube back in. Discontinued parts....some re-secure the broken ends with zip ties....some get a kit that has replacement lines made of flexible fuel hose (I think). The right tank line is 10337581 if you want to see what it looks like.

And yes to C6VetteLover....the crossover tube assembly includes the 10337588 feed and return line, which is also available separately (at least they used to be available)

I got pumps back in 2018 when my fuel sender gauge started acting up. Found a fix so never installed them....waiting for a fuel leak, if it comes.

I think 07-13 are the same for these 2 numbers with the correct level sensors attached 05-06 are different. MU1892 and MU2186.

 

NO !!…this may not be a cracked fuel pump module electrical connector flange issue so I’d highly recommend you smoke test first and if you can get your hands on a borescope you can confirm it is a leak up there…you don’t want to be pulling the tank for nothing…a P0442 is a SMALL EVAP leak and if that flange were cracked it would most likely be throwing a large leak code…a small leak is a .020 inch leak…that’s tiny !!…smaller than the width of a paper clip and may just be a pinhole leak in an EVAP hose.

 

Don't fill it past 1/2 tank . Problem solved

 

If I am correct, not too practical since the passenger tank fills last and empties first. To never get above 1/2 driver's tank, you could only drive about 90 miles between 4.5 gallon "fill ups'"

P0442 is common when the vapor cannister vent solenoid (at right rear wheel) fails.