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EVAP P0441 over tank parts list?

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Old 02 Nov 2015, 02:04 pm
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Join Date: Oct 2013
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Default EVAP P0441 over tank parts list?

We've had the all-too-common P0441. Unfortunately, for our "convenience", the state of Texas is requiring an inspection as a prerequisite of registration. Had previously swapped gas caps but of course that didnt work.

So, we are starting with the usual suspect, the NVLD, which will be here tomorrow. While the tank was down I figured I'd replace the rubber hoses as I'd read somewhere that they can crack. Here's my current list...

2' of 1" (27mm) inside diameter fuel filler hose
2' of 7mm (1/4") fuel hose (low pressure) for the vent tube.

I don't know the size of the hoses on top of the fuel tank or if they are so contorted that non-molded hoses are non-starters. The illustration of the top of the fuel tank on page 25-14 of the FSM suggests they aren't too contorted but illustrations rarely match reality. I thought I'd pick up some Permatex® PermaShield™ Fuel Resistant Gasket Dressing & Flange Sealant to dress the joints. I'll put a coat around the metal-to-plastic joint in the filler neck while it's all out as well.

Anything else I should add to my shopping list?

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Old 08 Nov 2015, 11:51 am
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Join Date: Oct 2013
Posts: 8
Default Re: EVAP P0441 over tank parts list?

Thought I'd close this thread in case someone searches in the future.

The rubber plumping on top of the tank was all in good condition and still flexible. They are tightly curved and premolded so replacing them with bulk fuel resistant hose would be challenging. But even being ten years old they are still pliable.

Getting the NVLD off was the hardest part of the job because the rubber hoses gripped it so tightly. Normally you can twist hoses to break the seal but my initial attempts failed to break the connection. I didnt want to risk tearing them since they seem to be unobtainable. Instead I used a small flat screwdriver to slowly separate them. Eventually I got them off but slow and steady saves the hoses.

Couple of pictures for reference...

You can see dampness around the fuel filler hose and two clamps from someone's attempt to seal it. My local auto parts store (a Federated store not a Walmart-style one) couldn't find 1" fuel hose in the Dayco or Gates catalogs. You can get it at (No really, that's a real thing ) as from other threads here you'll find FiatChrysler doesnt acknowledge there is a rubber hose in the fuel system.

We cleaned that area really well with SuperClean and then wax and grease remover. We then put two coats of the Permatex fuel resistant sealant over the area. We also noticed that the middle of the tank seems to have been repaired in the past. It wasn't wet so seems like it was well done.

While I don't have pictures, the vent tube (7mm or 1/4") had hard thin black plastic tubing coming from the vent nipple, then to a red fuel tubing and finally to the metal vent tube that goes to the metal fuel filler neck. The thin black plastic tubing was easy to spin so seems unlikely it sealed. We replaced it with 1/4" low pressure black rubber fuel hose.

Someone had mentioned in another post that at the top of the fuel filler metal pipe that connects to the fuel cap had a transition from metal to plastic and theirs leaked. On ours, an 05 vert, the entire fuel filler is metal with no transition to plastic. All I did to the filler neck was clean it and put the Permatex sealant at the welds in case they had pin holes from the welding when it was manufactured.

In case any one is interested in where the NVLD is, here is a photo from the passenger side wheel well with the tank lowered. One may be able to replace the NVLD by just lowering the right side but getting the hoses off of it may be incredibly difficult without room.

We reset the code with my code reader and after a couple of days no check engine light. Will need to attach the reader again to make sure the EVAP status has turned to "ready" before taking it in for inspection.

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