The last few times I gassed up my 2005 Pontiac Sunfire (2.2L Ecotec) I noticed that it was very hard to pump gas into the tank. I had to just let it trickle in. On Monday I put about 3/4 tank of gas into the tank and it pumped without issue. However, now I'm getting the P0445 code for a large leak in the EVAP system. I replaced the gas cap and cleared the code. I'm waiting to see if it comes back on. Is this a common issue with our cars? Replacing the gas cap was listed online as the most common culprit. However, the trickle fill I experienced at the pump during my previous fill ups has me worried that it may be something else. Is there something I should be looking for? Thanks for your help.

Not sure if it helps, but here is the underside of the car. Got to love the salted New England roads.

Not sure if it's a problem or design flaw but my cav does the same when filling but no issue with codes. I think it has something to do with air being in the tank. They're designed to expand with changing of temperatures


ReD RaiN

Looks like the code is back. Climbed under the car to check hoses and the wire harness. Nothing looks cracked, no leaks that I could tell. As you can see, harness looks okay. The filler tube is a bit rusted, but no leaks that I could make out. Wondering if it's a stuck solenoid. Hate to have to do it, but it looks like I may need to get a smoke test done on it. Would make the most sense instead of swapping parts any praying. Will probably have it done in the next couple weeks. I shouldn't have an issue driving it around, should I? I imagine the EVAP leak wouldn't make a difference, but emissions/inspection, correct?

Some pics: