P0440 Code in 2026: The General EVAP Fault, Software Before Parts, and the Purge Valve Behind the Stalls

P0440 is a code about a system, not a part.

The EVAP system stores the vapor that rises off the fuel in the tank. The vapor flows to a charcoal canister, and the engine computer later opens a purge valve and draws it into the intake to be burned. A vent valve lets fresh air in behind it, and a pressure sensor, a pump or a switch lets the computer test the whole thing for leaks. P0440 means one of those checks failed and the computer could not say where. Stellantis, the maker of Jeep, Dodge, Chrysler, Ram, Fiat and Alfa Romeo, prints it as "General EVAP System Failure" (or "Evaporative Emission System Incorrect Flow" on Alfa Romeos); Karma prints "EVAP System General Fault". Its neighbors name more: P0455 a large leak, P0456 a very small one, P0441 the purge flow, P0446 and P2422 the vent side, P0451 and P0452 the tank pressure sensor.

We read 114 documents in full — 64 distinct service bulletins, technical tips, special coverages and campaigns whose own text names P0440 or one of those neighbors, and 50 recall filings for 13 EVAP-related safety recalls — from Stellantis, Ford, GM, Honda, Acura, Toyota, Volkswagen, Audi, Subaru, Kia, Hyundai, Mazda, Jaguar, Land Rover, Porsche, Suzuki and Karma. Only 11 of the 64 bulletins name P0440 in their own text, and all 11 come from Stellantis or Karma. Nine of them are software flashes, a reprogram of the engine computer; the other two end at a connector. None of the 11 tells a technician to replace a part for P0440.

The federal complaint file shows the other side. Of 780,071 complaints received by NHTSA from 2015 to September 2026, only 13 name P0440. Owners write "evap" far more often than the code, and name the part more often still, so we went through every complaint our searches matched for P0440, EVAP wording or an EVAP part — 3,908 in all: 1,267 with the code or EVAP wording and 2,641 that name a part such as a purge valve, a gas cap or a canister, each sorted twice, independently, by the same written rules. 3,185 describe an EVAP fault. In 1,058 the engine stalled or would not start or restart; 848 describe a gasoline smell or liquid fuel; in 1,004 the light or the symptom came back after a repair.

By the end you will know which of five routes your P0440 is on, what each costs in 2026, whether a recall, special coverage or bulletin we went through applies to your vehicle, and the cheap step that gets skipped before a canister or a fuel tank is sold.

Claims marked 🟢 rest on a document listed in the Sources section, read in full. Claims marked ⚪ are shop-price estimates carried from our repair guides. Owner-reported figures are what people told NHTSA, published with ODI numbers, and every complaint count here comes from the 3,908 complaints sorted twice and published.

I built PulsCar after a $380 "full diagnostic" in Phuket in 2025 led to roughly $6,000 over six months across several shops (the story is on the About page). P0440 is a quiet version of that pattern: a code that names a system, a system with a dozen parts, and a cheap check that tells you which one before anything is bought.

What P0440 says: a vapor system that failed its own check

The system. 🟢 Volkswagen's recall papers describe one piece of it plainly: the suction jet pump inside the tank "is designed to purge fuel from the Evaporative Emissions (EVAP) system." 🟢 Ford's bulletin for the 2024-2026 Expedition and Navigator adds that "Under normal operating conditions, fuel in the EVAP canister is present as vapor." Liquid fuel in the canister is already a fault.

The test. Makers check the sealed system in different ways. 🟢 Audi's leak detection pump "pressurizes the EVAP system and monitors any pressure drop within a specified amount of time in order to detect a leak." 🟢 Subaru's leak check module pulls a vacuum instead, and Subaru's technical newsletter adds: "According to legal regulations, leaks of 0.02 inch or more need to be detectable." 🟢 GM's vent valve on its 2007-2010 full-size SUVs draws fresh air through a vent on the fuel filler pipe; dust and water that get in can restrict it.

What P0440 is not. It is not a leak size and not a part; none of the 11 documents that name it gives it its own test. When a technician says "P0440 means the canister" or "P0440 means the cap," the documents do not back either.

First: is it P0440, or a code that names the part?

Before any diagnosis, read every code, because the neighbors narrow the search that P0440 leaves open.

P0440 with P0455 or P0456 is a leak story: cap, filler neck, hoses, canister seams. P0440 with P0441 or P0496 points at purge flow. P0440 alone on a Stellantis vehicle is first a software question.

The EVAP code family, and how often owners name each

Of the 3,185 complaints that describe an EVAP fault, 208 name a code (13 of all 3,908 name P0440). The EVAP codes they name most often:

The maker atlas: who wrote about P0440 and its neighbors, and what they blamed

Stellantis: software first, then hoses and connectors. 🟢 P0440 appears in flash bulletins for the 2016 Fiat 500X, the 2015, 2016 and 2018 Jeep Renegade, the 2017-2018 Alfa Romeo Giulia, the 2019 Dodge Challenger SRT and its Challenger and Charger siblings, and a 2023 family for 2022 Challengers, Chargers and Chrysler 300s that prints "CAUSE: PCM Software." 🟢 A technician case, S2008000112, ends in a connector with "no parts required," and bulletin 25-002-15 replaces a split purge valve hose on 2015 Grand Cherokees and Durangos.

Ford: the Focus purge valve, and tanks. 🟢 Recalls for the 2012-2018 Focus and 2010-2011 Fusion and Milan; loose vent connectors inside 2024-2026 Expedition and Navigator tanks.

GM: purge valves, overfilling, water and seals. 🟢 Three purge valve special coverages; bulletins on topping off, water, a filler seal, a canister weld and tank vents.

Honda and Toyota: dust in the vent. 🟢 Honda's P2422 bulletins for the Accord, Ridgeline, Pilot and Passport say "Dirt may be clogging the EVAP canister vent tube"; Toyota's Corolla bulletin replaces the canister and adds a filter for P2420.

Volkswagen and Audi: codes that are not leaks, and fuel where vapor should be. 🟢 Software that set leak codes wrongly; a canister supplier's seams; a suction jet pump recall.

The others. 🟢 Subaru's leak check module, Kia's swelling K5 tanks, spiders and dust in Mazda and Suzuki vent lines, cracked hoses at Jaguar and Land Rover, and a tank valve connector at Karma.

The 10-minute P0440 check

1. Read every code, with freeze frame (2 minutes). P0440 alone, or with P0455, P0456, P0441, P0496, P2422, P1450 or a tank pressure code, points to different routes.

2. Look at the cap or the capless filler (2 minutes). Is the seal cracked or missing, the tether trapped under the cap, the flap sticking? 🟢 Volkswagen found "the fuel cap tether trapped under fuel cap" on Tiguans with P0442 and P0457.

3. Think about the last fill-up (1 minute). Did the car stall, idle rough or refuse to restart right after it? Did the pump click off early or fuel spit back? That separates Routes 4 and 5 from the rest.

4. Smell and look under the rear (2 minutes). Wet spots on the tank or filler neck, a drip near the canister: liquid fuel moves the car to the top of the triage box.

5. Run the VIN (3 minutes). At nhtsa.gov/recalls for the Ford, Volkswagen, Audi, Mazda, Suzuki and Honda recalls below, and with a dealer for special coverages, campaigns and software bulletins, which do not show up as safety recalls. A recall is free on a listed VIN; a special coverage is free until its years or miles run out; a bulletin is a repair instruction, paid by the warranty or by you.

Seven P0440 situations, and which is yours

"P0440 or P0457, and the cap was just off, loose or new." The cheapest route. → Route 1.

"P0440 on a Renegade, 500X, Giulia, Challenger, Charger or 300, the car drives fine." Stellantis has software bulletins. → Route 2.

"P0456 or P0442 on a Volkswagen, Audi or Subaru, and the smoke test finds nothing." Software and leak check modules. → Route 2.

"P0440 alone on another make, the cap looks fine, no smell, no stall." Book a smoke test; its result picks Route 3, 4 or 5.

"P2422 or P0446 on a Honda, Toyota or GM truck driven on dirt roads, or the tank is hard to fill." The vent side. → Route 3.

"The engine stalls or will not restart after a fill-up; P0441, P0496, P1450 or a jumping fuel gauge." The purge valve. → Route 4.

"The pump clicks off after a gallon, fuel spits back or drips, the tank looks crushed or swollen." The tank side. → Route 5.

The P0440 price ladder, from the bottom up

The ⚪ figures come from our P0455 guide, which prices each EVAP part; the owner figures are listed with ODI numbers in the published file.

What does it cost to fix P0440 in 2026, and when is a canister or a fuel tank the wrong purchase? Our P0455 guide carries a smoke test at $50 to $150, a purge valve at $150 to $300 installed and a canister at $200 to $650. In PulsCar's review of 3,908 federal complaints, owners report $100 to $2,113 for purge valve and purge pump jobs and $450 to $6,000 when a fuel tank or pump module was replaced or quoted for an EVAP fault, mostly quotes. A canister or tank is the wrong purchase when Stellantis has a software bulletin that lists P0440 for your vehicle, when a Volkswagen or Audi bulletin says the leak code was set by software, when the cap seal or a connector was never checked, and when a recall or special coverage such as Ford's 18V-735 or GM's purge valve programs covers the part for your VIN.

The five P0440 routes, cheapest first

Route 1 · The cap and the filler neck — $0 to $2,800

What it is. The system is sealed at the fuel cap or the capless flap. A cap left loose, a cracked seal, a tether caught under the cap, a filler neck rusted through or a seal pushed out of place lets the leak test fail.

What the documents say.

🟢 Volkswagen tech tip 01-21-01, 2019-2021 Tiguan 2.0. With P0442 or P0457 stored: "Cases have been found with the fuel cap tether trapped under fuel cap." The instruction limits the purchase: "The fuel cap should only be replaced if the seal is damaged, or the fuel cap no longer seals at the filler neck." And it does not stop at the cap: "Even if evidence of an incorrectly installed cap is found, ODIS diagnosis should still be completed to determine whether or not any other EVAP leaks are present in the system."

🟢 GM PI1034A, 2014 Chevrolet Impala. P0442 from a seal that was misplaced at the factory: "This condition is due to the seal on the fuel tank filler pipe housing not seated properly during vehicle assembly, causing a small EVAP leak". The repair: "Using a trim stick, push the seal over the filler neck and clear the DTC." GM prints 0.4 hours.

🟢 Volkswagen tech tip 01-19-09, 2018-2019 Atlas 3.6. For P0441, P0442, P0456 and P0496 after a software update: "One common leak frequently found is by pulling the rubber boot in the fuel filler door and checking the connections located there (canister breather line and filler neck collar)." 🟢 Stellantis case S2008000112 lists P0440 alongside "P0457 Loose Fuel Cap" — the loose-cap code travels with the general one.

What the owners report. 306 complaints end with a cap or filler neck as the cause; 259 of them name the part without writing "EVAP", and some report no more than a "check gas cap" message. A 2015 Grand Cherokee owner wrote only: "Fuel filler cap fell off... set code P0440." A 1998 Riviera owner found fuel under the car at the filler door and, behind the tire, "A HOLE IN THE FILLER NECK THE SIZE OF A US QUARTER." A 2015 Renegade shows the limit of this route: the owner smelled fuel through two clean smoke tests and a software update, then "found gas leaking from the rear wheel well"; a $500 filler neck stopped the leak, but the code "was cleared only to come back on the next morning." And caps are also where money is wasted: a 2011 Nitro owner paid $100 for a diagnosis, then bought factory caps — "RECOMMENDED FACTORY GAS CAP 6 CAPS LATER $140" — and still had the light, then a $300 purge valve.

The cheap cause that gets skipped. The cap seal and its tether, and on capless fillers the flap and the rubber boot around the neck. They are checked in a minute and cost nothing to look at.

Fix it yourself — what is honest. Take the cap off and look at the seal for cracks, flattening or dirt; make sure the tether is not under the seal; refit it until it clicks. On a capless filler, look for a flap that sticks open or a missing boot. Then drive a week: the light will not go out on the next trip, because the monitor has to run again. Replacing the cap is reasonable when the seal is damaged; buying a second and a third is not a diagnosis.

At the shop — say this: "Before anything else, can you inspect the cap seal, the filler neck and the boot at the filler door, and smoke-test the system if they look fine? What did the test show, and where?"

Route 2 · Software, a connector, or the leak-check module — $0 under warranty, labor outside it

What it is. The engine computer runs the EVAP test. If its software times the test wrongly, reads a sensor wrongly, or a connector loses contact, it sets a code with nothing leaking. On some cars the leak check pump or module itself is the fault. This is where P0440 lives in the documents.

What the documents say.

🟢 Stellantis flash bulletins that name P0440. 08-010-16 REV. D for the 2016 Fiat 500X lists "P0440 - General EVAP System Failure." among 27 codes for the engine computer, and so do 18-063-16 (2015 Renegade), 18-061-16 REV. C (2016 Renegade 2.4) and 18-044-21 (2018 Renegade 1.4 turbo). The Alfa Romeo Giulia bulletins 18-030-17, 18-030-17 REV. D and 18-097-19 print the code as "P0440 - Evaporative Emission System Incorrect Flow." In every one, the repair is to reprogram the engine computer; the labor printed for that is 0.2 to 0.4 hours.

🟢 Stellantis 18-064-22 and its siblings, the 2019 Dodge Challenger SRT and other Challenger and Charger models, and 18-091-23 and its siblings for the 2022 Challenger, Charger and Chrysler 300. Short lists with only four EVAP codes: P0440, P0455, P0456 and, depending on the bulletin, P0441 or P0452. The 2023 family prints its cause in one line: "CAUSE: PCM Software". The 18-064-22 family tells technicians to test before believing a leak: "NOTE: If DTC P0456 is present use the wiTECH Small Leak Verification test (SLVT) to determine if a leak is present in the system."

🟢 Two connectors. Stellantis's case S2008000112 starts from "P0440 General Evaporative System Failure along with leak detected faults P0457 Loose Fuel Cap, P0456 Small Leak Detected" and ends: "Inspect connector XY465A for any signs of spread or pushed out terminals, secure the connector and terminals as needed, no parts required." 🟢 Karma's SC-18-01-01 for the 2017-2018 Revero, titled "Evaporative Emission System (EVAP) Inspection," lists P0440 among four codes and says: "In addition to normal diagnostic procedures and tests you may inspect the FTIV Valve connection ensure this is seated and connected properly."

🟢 Volkswagen and Audi: leak codes that are not leaks. 01-21-09, 2018-2021 Atlas and 2020-2021 Atlas Cross Sport: "Current Engine/Motor Control Module -J623- software is allowing the diagnosis of some EVAP faults to run during refuel, leading to erroneous fault codes being stored." The bulletin's instruction: "DO NOT diagnose or replace components due to the above faults before performing the update function as explained in this bulletin." Audi's 2027732 family for the 2010-2011 A8 4.2 and 2012 A6 and A7 3.0 is titled "MIL on, no leak in EVAP system". Volkswagen's 23X1 update for the 2018 Atlas: the software "does not properly operate the Leak Detection Pump heater circuit," letting moisture into the pump and causing "erroneous EVAP fault codes." 2070690 and 2078397 cover P0456 and other EVAP codes on 2022-2024 Taos and Jetta 1.5T models, with the same order: update first.

🟢 Leak-check pumps and modules. Audi 2035519/2, 2013-2014 Q7: pressurize the system to 12 inches of water and check after 3 minutes; if 9 inches or more remain, "the system has no leaks," so the fault is the pump, and it is replaced. Subaru's leak check module bulletins — 09-102-23 for the 2022 WRX, 09-109-23 for 2016-2019 Legacy and Outback, 09-122-24R for Forester, Legacy, Outback, Impreza and Crosstrek — reprogram for P2404 and replace the module only after a retest fails. The WRX bulletin says "P2404 is caused by the internal pump of the Evaporate Leak Check Module (ELCM) being temporarily stuck/seized." Subaru's technical newsletter warns: "Never put pressure into the ELCM or use smoke as residual oil in the smoke can contaminate the ELCM and cause internal components to malfunction." 🟢 GM 25-NA-025, 2025-2026 Encore GX, Envista, Trailblazer and Trax: a short to power in the wiring to the leak pump; wiring first, the pump only if the wiring is fine.

What the owners report. 82 complaints were sorted under a sensor, a pump, wiring or software as the cause. A 2016 Renegade owner with P0440: the dealer replaced "A FRONT VACUUM VALVE"; "THREE DAYS LATER THE CHECK ENGINE LIGHT WAS BACK ON." — and the dealer then blamed a pressure switch in the tank. A 2020 CR-V owner was told a bulletin applied: "radio interference in the environment can trigger a fault in the evap syatem"; out of warranty, they paid over $330 for an added wiring harness. Software is not always the end: a 2021 Atlas Cross Sport had its purge solenoid replaced and then a software update, and the light came back for the same EVAP fault.

The cheap cause that gets skipped. The software level and the connector. A dealer can compare the engine computer's software with the latest in minutes; on the Stellantis, Volkswagen, Audi and Subaru vehicles above, that is the repair or the first step of it.

At the shop — say this: "Is there a bulletin that names P0440, or the EVAP codes I have, for my VIN? Is the engine computer on the latest software? Please update it and check the connectors before any EVAP part is ordered."

Route 3 · The vent side and the canister — $14 to $2,000

What it is. Fresh air enters the canister through a vent valve and, on many cars, a filter or drain tube. Dust, water, spider webs, a cracked hose or a leaking canister seam blocks the vent or opens the system. A blocked vent can also make the tank hard to fill.

What the documents say.

🟢 Honda: dirt in the vent tube. Bulletins for the 2013-2017 Accord (A15-010), the 2017-2022 Ridgeline (20-002), and the 2016-2022 Pilot and 2019-2022 Passport (20-056) give one cause for P2422, "EVAP canister vent shut valve stuck closed malfunction": "Dirt may be clogging the EVAP canister vent tube." The repair is a new canister and a drain kit with a filter box; the Accord bulletin prints 0.6 hours. Honda's tech line article ATS160701 adds the pattern behind it: "We’re aware that when driving regularly on dirt roads in very dry and dusty conditions, there can be repeated occurrences of the MIL coming on with DTC P2422 (EVAP canister vent shut valve stuck closed malfunction)."

🟢 Toyota T-SB-0024-15 Rev1, 2014-2018 Corolla with the 2ZR engines. P2420, the pressure switching valve stuck off: a new charcoal canister and a new filter sub-assembly, 0.7 hours, "covered under the Toyota Federal Emissions Warranty" for 36 months or 36,000 miles.

🟢 GM: water and dust. 17-NA-233, 2016-2017 Cruze with the LE2: P0446 from "water trapped in the evaporative emission canister" filter pipe, fixed with a boot on the connector, 0.4 hours. 09-06-04-028D, 2007-2010 Escalade, Avalanche, Suburban, Tahoe and Yukon: "MIL Illuminated, DTC P0442, P0446, P0455 or P0449 Set – Fuel Tank Hard to Fill – Moisture, Water, Corrosion at EVAP CVS Valve." The vent valve is replaced with a sealed design and a remote filter; the canister stays unless it fails the leak test.

🟢 Hoses and seams. Jaguar JTB00506NAS2 for the F-TYPE and Land Rover LTB00970NAS1 for 2015-2016 Range Rovers: "This may be caused by the hose from the Diagnostic Module Tank Leakage (DMTL) pump to the evaporative emissions canister - secondary becoming deteriorated and cracked." And a guard against a wrong purchase: "If DTC P0442-00 or P0456-00 is not present, this is not the cause of the customer concern and you should not continue with this Technical Service Bulletin." Volkswagen tech tip 20-23-01: "Some Model Year 2022 and 2023 Atlas vehicles built with EVAP canisters from supplier Leehan have been identified having EVAP leaks due to manufacturing defects." GM 22-NA-217, 2021-2022 Encore and Trax: P0442 from a plastic welding error in the purge canister, "which creates a small leak in the EVAP system," replaced only if it fails a smoke test.

🟢 Spiders and dust, as safety recalls. Mazda recalls 11V-134 (2009-2010 Mazda6 2.5, 52,000 vehicles) and 14V-114 (2010-2012 Mazda6 2.5, about 42,000); the second says "spiders may weave a web in the evaporative canister vent hose, blocking it and causing the fuel tank to have an excessive amount of negative pressure," which could crack the tank. Suzuki's 14V-464 for the 2010-2013 Kizashi fitted a vent line with a filter for the same spiders; 18V-769 later replaced the fuel tank on 21,052 Kizashis for dust in the vent hose and filter. Mazda's 20V-347, 12,097 all-wheel-drive 2020 CX-30s: a tank vent hose disconnected at the tank plant, letting liquid fuel fill and leak from the canister vent.

What the owners report. 270 complaints were sorted under the vent side or the canister as the cause; Toyota leads with 53, then Ford with 43. A 2010 RAV4 owner's dealer found water in the charcoal canister: about $1,000 in parts and over $500 in labor, and among the parts "A $14 PART TO COVER THE CANISTER AND PREVENT WATER ON THE ROAD FROM CONTAMINATING AND RUINING THE REPLACEMENT CHARCOAL CANISTER." A 2016 Civic owner had P2422 twice in a year: "DUST AND DIRT WILL COLLECT AND CLOG THE SYSTEM." A 2012 Impreza owner's dealer found spider webs in the EVAP drain and valve assembly and replaced it for $617.28.

The cheap cause that gets skipped. The filter, the drain tube and the boot. On the Hondas, Toyotas and GM vehicles above, the maker's fix includes a filter or a seal that keeps the next canister alive; a canister without it can fail the same way.

Fix it yourself — the honest split. Looking is a driveway job on many cars: the canister's vent filter or drain tube for packed dirt, water or webs, and the hoses you can reach for cracks. Keep sparks and flames away from fuel vapor, and never work under a car held only by a jack. Replacing a canister often means dropping the spare tire or a crossmember — Honda's Pilot bulletin has the technician remove the crossmember center brace — and is usually a lift job.

At the shop — say this: "Does the vent side pass its test, and was the vent filter or drain tube clogged? If the canister is replaced, does the maker's bulletin add a filter, a boot or a drain kit, and is it included?"

Route 4 · The purge valve, and the recalls behind it — $0 in a recall to $2,113

What it is. The purge valve opens to let the engine draw vapor from the canister. If it sticks open, vapor — and on a full tank a flood of it — goes straight into the intake, and the engine vacuum pulls on the tank. The results in the documents: a rough idle, a stall, a no-start after refuelling, and on some cars a deformed or cracked plastic tank.

What the documents say.

🟢 Ford recall 18V-735, 1,282,596 Focus models from 2012 to 2018 with the 2.0-liter GDI and GTDI engines. The dealer bulletin: "In some of the affected vehicles, the engine may stall due to a stuck canister purge valve (CPV) within the fuel vapor system." And: "A stuck CPV can lead to excessive vacuum in the fuel vapor system, causing the plastic fuel tank to deform, resulting in an inaccurate or erratic fuel gauge indication, inaccurate distance to empty (DTE), and/or other drivability concerns." The codes it lists are P0420, P1450, P0443, P0452, P0456, P0460 and P2196 — not P0440; recalls go by VIN, not by code, so run the VIN whatever code a Focus shows. Dealers reprogram the engine computer, replace the purge valve if codes or complaints are present, replace the canister if it holds liquid fuel, and replace the tank and fuel delivery module if the tank has deformed more than 1 inch. Until the repair, NHTSA's acknowledgement notes: "owners are advised to keep the fuel tank at least halfway full."

🟢 Ford 19V-515, 57,488 vehicles. Certain 2012 and 2017 Focus models and 2013-2014 Focus ST models already repaired under 18V-735: "The affected vehicles did not have the Powertrain Control Module (PCM) updated as intended." 🟢 Ford 26V-369, filed in June 2026, 257,868 Focus models from 2012 to 2018 in the amended July report: "certain 2012-2018 MY Focus vehicles did not have the remedy for Safety Recall 18S32 / 18V735 installed correctly, but were recorded as having the repair successfully completed." The owner letter dated July 2026: the software for Safety Recall 18S32 "may not have been installed correctly during a prior dealership visit." The remedy is the software again, with a verification step.

🟢 Ford 15V-793, 411,205 vehicles, 2010-2011 Fusion and Milan. "fuel vapor canisters whose purge valves may not operate properly resulting in abnormal pressure changes in the fuel tank," which could crack the tank; dealers update the engine computer, leak-test the purge valve, inspect the tank, and replace parts as needed.

🟢 GM special coverages N192210240, N222369620 and N232395300. The first covers the 2018 Buick Cascada, the 2016 LaCrosse and Cruze, and 2016-2017 Encore, Enclave, Caprice, Impala, Sonic, Traverse, Trax and GMC Acadia models, about 1,171,046 U.S. vehicles; the third, certain 2019 Enclave and Traverse 3.6 and 2020 Encore, Sonic and Trax 1.4 models, about 383,000. Each describes "a condition that could cause the evaporative emissions purge valve to not fully close," with a rough run, a hesitation or a stall at idle and a check engine light, and lists P0496, P0442, P0455, P0171 or P0174 as the codes a car may arrive with. Inside each coverage period the dealer replaces the valve free when its diagnostics lead to it; for most 2016-2017 cars under N192210240 that period has ended or ends soon. N222369620 does the same for the 2019 Cadillac XTS and 2020 Impala.

🟢 The same valve, other causes. GM's PI0898, 2013 XTS with P0455: "This condition may be caused by over filling (topping off) the fuel tank or by filling the fuel tank using a damaged service station fuel fill nozzle." GM's PIP4891H for the Volt, Ampera and ELR blames overfilling plus a big temperature swing for P0497 and warns against topping off: "Any more than three more pump "clicks" would be considered excessive." Stellantis 25-002-15 REV. A: a split purge valve hose on 2015 Grand Cherokees and Durangos, 0.3 hours.

What the owners report. 866 complaints were sorted under the purge side as the cause, 669 of them Fords; in 449, the engine stalled or would not start. The Focus alone accounts for 541 of the 3,185 complaints and 356 of the 1,058 stalls. A 2012 Focus stalled on an interstate and was towed; months later the dealer "DIAGNOSED AS EVAPORATIVE PURGE VALVE FAILURE CAUSING FUEL TANK TO COLLAPSE AND OTHER DAMAGE" — $2,113.42. A 2016 Focus owner paid $671.39 for a purge valve, learned the part was the 18V-735 part, and was refused a refund because a previous owner's recall repair was on record. A 2017 Acadia owner under GM's N192210240 had the valve replaced three times; each time "my vehicle stalls immediately after refueling," and on the third the dealer asked $189.99 for a diagnosis. A 2021 Envision owner replaced a purge pump and "only paid the $100 deductible" on a $404 job.

The cheap cause that gets skipped. The recall and coverage check, and the software in it. On a Focus the remedy starts with the engine computer; 19V-515 exists because the first repair's software was incomplete, and 26V-369 because the repair was recorded as done on cars that did not get it.

At the shop — say this: "Is my VIN in 18V-735, 19V-515, 26V-369 or one of GM's purge valve special coverages — and if the recall shows as done, can you verify the software level? Is the canister holding liquid fuel, and has the tank deformed?"

Route 5 · The tank, its valves, and fuel where only vapor should be — $450 to $6,000

What it is. Valves on or in the tank keep liquid fuel out of the vapor side: rollover valves, a fill-limit or shut valve, and on some Volkswagens a suction jet pump that returns fuel from the EVAP side. When one fails, liquid fuel reaches the canister, the pump clicks off early or spits fuel back, fuel drips from the canister vent, or the tank swells or collapses. Many of these parts are sold only with the tank.

What the documents say.

🟢 Volkswagen and Audi recalls 16V-647 and 24V-110. The 2016 filing covers 110,042 2015-2016 Golf, GTI and Golf SportWagen PZEV models and A3 1.8T front-wheel-drive models; its owner letter warns: "you may experience refueling issues (early stopping of the fuel nozzle and fuel spillback) when fuel accumulates in the EVAP system." The 2024 recall covers 261,257 vehicles — 2015-2020 Audi A3, Golf and GTI, 2015-2019 Golf SportWagen and 2019-2020 Jetta GLI: "Due to a problem with a suction jet pump seal inside the fuel tank, fuel may flow into the evaporative emissions (EVAP) system and possibly leak out of the charcoal canister." Dealers replace the suction pump free, and "Vehicles that were previously recalled under 16V-647 will need to have the new remedy completed." The quarterly report of 29 July 2026 shows 148,738 of the 261,257 remedied.

🟢 Kia campaign SC288, 2021-2024 K5 with the 1.6 turbo built 27 March 2020 to 17 October 2023. "The subject vehicles may experience fuel tank swelling due to an issue with the PCSV check valve, which results in pressurized air to flow into the fuel tank." The check engine light, a rough run and an inability to refuel can follow. Revision 1, since replaced, told dealers while no repair existed: "Vehicles with DTC P0451 stored will need to be parked until this TSB is revised to include the repair procedure." Revision 3 (SC288 R3) replaced the code check with a pressure and bubble test of the check valve.

🟢 Tanks that must be replaced whole. GM 21-NA-180, 2021-2022 Express and Savana with the 57-gallon tank, P0455 or P0442 and possible water in the fuel: "DO NOT try to remove and reinstall the fuel tank evaporative vents. The proper repair requires the fuel tank to be replaced." 🟢 Ford 26-2023, 2024-2026 Expedition and Navigator with P2418:72 or P2450: "This may be due to improperly connected EVAP line connections inside the fuel tank." After the canister comes off, the next step: "Inspect the EVAP canister for any accumulation of liquid fuel. Is liquid fuel present?"

🟢 Valves that click the pump off. Mazda SA-047-26, 2025-2026 CX-50 Hybrid: "The gas pump dispenser/nozzle is clicking off during refueling before the tank is full and it may take 1/2 to 1 gallon at a time," from a shut valve sticking; 0.5 hours to replace it. 🟢 Ford's special service messages 53601 and 53982 on P2450 in 2020-2025 hybrids: "This may be due to an evaporative emission system concern or may also be caused by the customer overfilling the fuel tank." 🟢 Honda recalls 11V-176 (18,056 2011 Civics, a rollover valve that could let fuel into the canister in a rollover) and 21V-010 (1,258 2018-2021 Odysseys with a fuel tank assembly installed by the converter, BraunAbility, that may overfill into the charcoal canister).

What the owners report. 534 complaints were sorted under the tank, lines or liquid fuel as the cause; in 336 of them the owner smelled fuel or saw it. Volkswagen and Audi account for 250 of the 3,185 complaints, and 38 of those mention a suction pump. A 2017 Golf owner's pump shut off after less than a gallon, and "gas would back up and flow down the over flow tube onto the ground"; they paid $3,896.69 for a tank, canister and parts. Two stories we sorted under the canister side still ended in tank quotes or bills: a 2018 TT RS owner was quoted $6,000, "the fuel is no longer going into my car, but rather leaking out the excess drain hole." and a 2017 Durango owner was billed $2,700 for a tank and canister. And a 2007 Chrysler 300 owner with P0440 found the cause themselves: "ROLLOVER VALVE POPPED OFF AND THERE WAS FUEL ALL AROUND IT."

The cheap cause that gets skipped. The recall lookup, and the habit of topping off. GM's bulletins and Ford's hybrid messages name the driver's overfilling as a cause; on the Volkswagens, a tank job may be a free suction pump.

At the shop — say this: "Is there liquid fuel in the canister, and where did it come from? Is my VIN in 24V-110, SC288 or another campaign? If the tank has to be replaced, which valve failed, and is it sold separately?"

Is anything covering P0440 in September 2026?

The status column is our own calculation from the terms printed in each document, as of September 2026 — not a statement by the manufacturer. Check the exact VIN.

How we computed the GM rows. N192210240 runs "for a period of 10 years or 150,000 miles" for the Acadia, Cascada, Enclave and Traverse and 10 years or 120,000 miles for the others, from the date each vehicle was first put in service; a 2016 model first used in 2015 or 2016 reached 10 years in 2025 or 2026. The reimbursement deadline for earlier paid repairs, 30 September 2020, has passed. N232395300 runs "for a period of 15 years or 150,000 miles", "whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership" — into the 2030s for 2019 and 2020 models.

No coverage extension names P0440. The Stellantis bulletins that list it are repairs under the vehicle's warranty; outside it, the owner pays for the flash. Toyota and Mazda print their emissions or new-vehicle warranty on the bulletin itself. Our P0455 guide covers the federal and California emissions warranty terms, which decide whether a purge valve or canister is covered on a car without a program.

What 3,908 complaints about the EVAP system show

We went through every complaint our searches matched for P0440 in any spelling, EVAP wording such as "evap leak", or an EVAP part name: 3,908. The first search found 1,217; a second, independent search found 50 more EVAP spellings and 2,641 complaints that name a part — a purge valve, a gas cap, a canister, a vent valve — without EVAP wording or the code. We sorted those in a second wave under an addendum to the sorting rules, fixed before that sorting, that kept every category and rule; the method file gives each search.

Every complaint was sorted twice, independently, by the same written rules, fixed before the sorting started. On the first 1,267 the two sortings matched on the category for 943 (74%); on the 2,641 of the second wave, with the first wave's rules in hand, for 2,214 (84%). Every disagreement was settled under 15 written rules, and the published file carries both sortings, the final one, and which search found each complaint.

723 of the 3,908 turned out not to be EVAP stories — an EVAP code in a list behind a transmission, a coolant leak or an electrical failure, a purge valve among parts thrown at a stall, a fuel door that would not open, or an air-conditioning complaint. That leaves 3,185.

The cap moves up once owners name the part. Among complaints that write "EVAP" or the code, 47 of 990 end with a cap or filler neck, fewer than any other named cause except sensors, pumps, wiring and software (44); among those found by a part name, 259 of 2,195. Across both, 306 end with a cap, against 866 with a purge valve and 534 with the tank side; sensors, pumps, wiring and software remain the smallest group, 82. A search built from part names finds named parts more often, so these shares describe how owners write, not how often parts fail — and a cap that fixed the light rarely prompts a complaint.

Nearly a third came back. In 1,004 of the 3,185, a repair was made and the same light, code, smell or symptom came back; 603 of them are in the unresolved group.

The makes and the years. Ford leads with 1,205 of the 3,185, then Chevrolet with 325, Jeep with 223, Volkswagen with 201 and Dodge with 155. The Focus is the most frequent model with 541, then the Fusion with 206 and the Escape with 196. The median model year is 2014; of the 1,827 complaints that give a mileage, the median is 76,000 miles. By year received: 224 in 2015, 253 in 2016, 228 in 2017, 259 in 2018, 316 in 2019, 264 in 2020, 222 in 2021, 265 in 2022, 305 in 2023, 329 in 2024, 293 in 2025 and 227 in 2026 to 21 September.

Counting complaints, not cars. A complaint records what an owner experienced and was told, not an established cause.

What do 3,908 federal complaints about the EVAP system show, and how often is it only the gas cap? In PulsCar's review of every complaint our searches matched for P0440, EVAP wording or an EVAP part name, each was sorted twice, independently, by the same written rules, and the two sortings matched on the category for 3,157 of 3,908 (81%). 3,185 describe an EVAP fault. 306 end with a cap or filler neck as the cause, against 866 with a purge valve, 534 with the tank, its valves or liquid fuel, 270 with the vent side or canister and 82 with a sensor, pump, wiring or software; 662 ended unresolved after at least one repair or diagnosis. 1,058 describe a stall or no-start, 848 a gasoline smell or liquid fuel, and in 1,004 the light or symptom returned after a repair. Only 13 name P0440 by number.

When it stalls or smells: the safety side of an EVAP fault

1,058 of the 3,185 describe a stall or a no-start. 337 of them use a refuelling phrase — "after filling up," "after refueling." The purge side accounts for 449 of the 1,058; Ford for 644, the Focus alone for 356. 🟢 Ford's 19V-515 acknowledgement describes the risk for the Focus: an engine stall while driving, without warning and without the ability to restart, from excessive vacuum in the fuel vapor system.

848 describe a gasoline smell or liquid fuel. 336 of them are tank-side stories. 🟢 The Volkswagen and Audi recall documents put it plainly: fuel in the EVAP system "could, over time, accumulate and cause a leak through the charcoal canister filter element. Leaking fuel, in the presence of an ignition source, may result in a fire." 🟢 Ford's 15V-793 owner letter says a cracked tank "may result in a fuel odor or leak."

467 describe a tank that was hard to fill, spat fuel back, or deformed.

What to do. A gasoline smell in the cabin or garage, or fuel on the ground: park outdoors and have it inspected before driving. Do not top off the tank after the pump clicks off — 🟢 GM's XTS and Volt bulletins and Ford's hybrid messages name overfilling — and on a car that stalls after refuelling, keep the tank at least half full until the recall or repair is done, as NHTSA's letter advised Focus owners.

What owners say they paid

We collected the dollar figures for EVAP diagnoses, repairs and quotes from the relevant complaints, leaving out rentals, towing and vehicle prices — 336 figures from 293 complaints, 173 of them quotes — and the full list with ODI numbers is published.

A diagnosis or a test. $175 quoted for a smoke test on a 2009 DTS; $539.91 to drop a 2016 Sierra's tank, with no fault found; $1,500 quoted to drop a 2023 Highlander's.

A cap, a filler neck, a purge valve. Six factory caps for $140 on the Nitro; $500 for a 2015 Renegade's filler neck; $629.97 billed for a 2013 Escape's purge valve stuck open; $671.39 for a 2016 Focus's, later found to be the recall part; $729.46 for a 2024 Trax's purge pump.

A canister or vent valve. $300 for a 2007 Silverado's vent solenoid, after which P0449 came back; $1,100 for a 2017 Pilot's canister outside warranty; $1,500 on each of three 2010 RAV4s; over $2,000 quoted for a 2014 Corolla's charcoal filter.

A tank. $2,242.24 billed for a 2014 Fusion's tank after a discount, because a seal was not sold separately; $2,700 for a 2017 Durango's tank and canister; $3,896.69 for a 2017 Golf's; $6,000 quoted for a 2018 TT RS.

Why P0440 comes back after a repair

Because the part was not the cause. 🟢 Volkswagen and Audi bulletins say software set EVAP codes with nothing leaking and tell technicians not to replace parts before the update; a canister or valve bought first changes nothing.

Because the remedy was not installed. 🟢 Ford filed 19V-515 in 2019 because the first Focus repair's software was incomplete, and 26V-369 in 2026 because the repair was recorded as done on cars that did not get it.

Because the conditions came back. 🟢 Honda's dirt-road article describes "repeated occurrences" of P2422 for drivers on dusty roads, and the canister is replaced with a filter box for that reason; GM's PI0898 asks dealers to tell the customer "that over filling the fuel tank may lead to a repeat concern."

Why does P0440 keep coming back after a new gas cap, purge valve or canister? In PulsCar's review of 114 documents and 3,908 federal complaints, a reason the documents give again and again is that the part was not the cause. Stellantis fixes the P0440 in its bulletins by reprogramming the engine computer, and one of its cases ends with a connector and no parts. Volkswagen and Audi bulletins say software set EVAP leak codes on Atlas, Jetta, Taos and A6 models and forbid replacing parts before the update. Ford refiled the Focus purge valve recall twice because the first repair's software was incomplete. Dust returns to Honda vent tubes, and overfilling floods GM canisters again. In the complaint file, 1,004 of 3,185 describe a light or symptom that returned after a repair. Before another part, ask for the software level, the recall status and a test that shows where the fault is.

Can you drive with P0440?

It depends on what the car does, not on the code. A P0440 with a steady light, a car that starts and runs normally and no fuel smell is a diagnosis to book this week; make sure the cap clicks and stop topping off. Fuel dripping or a strong gasoline smell means do not drive it: park it outdoors and have it inspected. A stall or no-start after refuelling, or a gauge that jumps, means stop topping off and have it checked within days; Ford's 19V-515 papers describe a Focus stall without warning.

Should you buy a used car with a P0440 history?

Yes, if the fix is on paper and the readiness monitors read ready. A receipt for a named repair — a software bulletin, a recall remedy with the software verified, a filter kit with a canister — is a good sign. "Cleared the code" or "new gas cap" is not, and a monitor that is not ready can mean the codes were just cleared.

Four checks before you buy. Run the VIN for the recalls above, including 26V-369 on any 2012-2018 Focus; have the readiness monitors read with a scanner; fill the tank at a pump and watch for early click-off, spit-back and a rough idle afterwards; and look under the rear for fuel stains at the tank and filler neck.

Clearing P0440 before an inspection

It will not get you through. Erasing codes resets the readiness monitors, and a fault that is still there sets the code again. A car presented with incomplete monitors can be turned away or failed.

What works instead. Find the route, fix it, and drive normally for a week or more before the test; our inspection cost guide covers re-test fees.

What a shop actually does with a P0440, checkpoint by checkpoint

Checkpoint 1: codes and data — every code with freeze frame, the fuel level, the tank pressure reading.

Checkpoint 2: bulletins, recalls and software — by VIN, for the engine computer.

Checkpoint 3: the cap and filler — seal, tether, neck, boot.

Checkpoint 4: a test — a smoke test, or the maker's own leak test where smoke is forbidden, as on Subaru's leak check module.

Checkpoint 5: the purge and vent valves — commanded with a scan tool, and the canister checked for liquid fuel.

Checkpoint 6: the part — only now, with the test that condemned it written on the estimate.

Three P0440 traps that cost owners the most

Trap 1: caps bought as a diagnosis. A cap costs little, but the Nitro owner above bought six. Lesson: one good cap, then a test.

Trap 2: parts before software. On the Stellantis and Volkswagen vehicles above, the documented fix is a flash; a canister bought first comes back as the same code. Lesson: ask for the software level first.

Trap 3: a recall marked done. Two Ford recalls exist because a remedy on record was not installed. Lesson: ask the dealer to verify the software, not only the recall status.

Three P0440 quotes, decoded

These are composite scenarios, not individual customers: each combines details from the documents and owner reports above; the dollar figures are drawn from the ranges on the price ladder above.

Scenario 1: 2016 Jeep Renegade 2.4, 70,000 miles, P0440 with P0456, quote for a canister. The owner asks for the software level first, and whether the flash is covered. Bulletin 18-061-16 REV. C lists both codes; after the reprogram, the code does not return. Lesson: on a Stellantis vehicle, the flash comes before any EVAP part.

Scenario 2: 2014 Ford Focus 2.0, 95,000 miles, stalls after refuelling, P1450, a gauge that jumps, quote for a purge valve and tank. The VIN shows 18V-735 recorded as done; the dealer updates the software under 26V-369 and, if the symptoms persist, replaces the purge valve and inspects the tank under 18V-735 or 24N07. Lesson: a recall on record is not the same as a remedy installed.

Scenario 3: 2017 Honda Pilot, 110,000 miles, P2422 after a summer of gravel roads, quote for a canister. A second shop confirms dirt in the vent tube and quotes the canister with Honda's drain kit and filter box from the bulletin. Lesson: the filter keeps the new canister from clogging again.

The P0440 plan: 10 minutes, today, this week

10 minutes: read every code; check the cap seal and tether; think back to the last fill-up; smell and look under the rear.

Today: if fuel is dripping, park it outdoors and arrange an inspection; if it stalls after refuelling, stop topping off and book a check within days. Otherwise, run the VIN at nhtsa.gov/recalls and ask a dealer for campaigns and bulletins for the vehicles in the triage box.

This week: have the software level checked, the system tested — with smoke where the maker allows it — and get the test that condemned any part written on the estimate.

Sources and documents

Primary documents only. Where a claim in this guide is marked 🟢, it rests on one of the items below, and the reference is given so you can pull the document yourself. Claims marked ⚪ are shop-price estimates carried from PulsCar's repair guides — estimates, not measurements from a dataset we own.

1. Stellantis flash bulletins 08-010-16 REV. D, 18-061-16 REV. C, 18-063-16, 18-030-17, 18-030-17 REV. D, 18-097-19, 18-027-20, 18-044-21, 18-064-22, 18-065-22, 18-066-22, 18-074-22, 18-090-23, 18-091-23, 18-093-23, 18-092-23, 18-094-23, 18-095-23, 18-096-23, 18-053-16; bulletin 25-002-15 REV. A; STAR case S2008000112; parts note 9003665. Karma SC-18-01-01.
2. Ford recalls 18V-735, 19V-515, 26V-369 and 15V-793 (Part 573 reports, acknowledgements, owner letters, dealer instructions); bulletins 26-2023 and 26-2238; special service messages 53601 and 53982.
3. GM special coverages N192210240, N222369620 and N232395300; PI0898, PIP4891F and PIP4891H, PI1034A, 17-NA-233, 09-06-04-028D, 21-NA-180, 22-NA-217, 25-NA-025, PIE0517.
4. Volkswagen and Audi recalls 16V-647 and 24V-110; Volkswagen V011617, 23X1, tech tips 01-19-09 and revision 2, 01-20-01, 01-21-01, 01-21-09, 20-23-01, 2070690/3, 2078397/5; Audi 2035519/2 and /4, 2027732/10.
5. Honda and Acura ATS160701, 15-010, A15-010, 20-002 and version 3, A20-056, 20-056 version 3 and version 4, Acura emissions recall 22-007; recalls 11V-176 and 21V-010. Toyota T-SB-0024-15 and Rev1.
6. Subaru TechTIPS evaporative diagnostics, 09-102-23, 09-109-23, 09-122-24R and its January 2025 revision, 09-128-24R. Kia campaign SC288 Rev 1 and Rev 3. Hyundai campaign 962, 21-01-009H. Mazda SA-047-26; recalls 11V-134, 14V-114 and 20V-347. Suzuki recalls 14V-464 and 18V-769. Jaguar JTB00506NAS2; Land Rover LTB00970NAS1; Porsche bulletin 2205.
7. PulsCar analysis of NHTSA public data, September 2026: 3,908 complaints our searches matched for P0440, EVAP wording or an EVAP part name, each sorted twice by the same written rules, with both sortings and every settled disagreement; owner-reported amounts; the list of 1,859 documents both searches found (bulletins, recall filings and audit finds), with check status. The sorting rules, data and how we did it, documents.

For the neighboring pages: P0455, P0456, P0442, P0441, P0446, a car that smells like gas, what a diagnostic should cost, inspection costs and the code index.

Methodology. The complaint set is every complaint in NHTSA's file, received from 2015 to 21 September 2026, that our searches matched for P0440 (with spellings using a letter O, a space, a suffix or a bare number after "code"), EVAP wording or an EVAP part name — 3,908 in all, 3,185 of them relevant: 1,217 from the first search, and 50 plus 2,641 from a second, independent search, the 2,641 sorted in a second wave. Every complaint was sorted twice, independently, by the same written rules, fixed and dated before the sorting, with an addendum fixed before the second wave (the two sortings matched on the category for 943 of 1,267, 74%, and 2,214 of 2,641, 84%), and every disagreement was settled under written rules published with the data. Of the 663 manufacturer communications our search found, 64 distinct bulletins that name P0440 or a companion EVAP code were gone through in full with their revisions, and 50 filings for 13 recalls; the others were screened and are listed. Every complaint quoted, and every dollar figure, was checked in full. Coverage status is our computation from the printed terms, as of September 2026. Nothing here is a failure rate.

Prices verified July to September 2026 in the repair guides they are carried from, and reviewed quarterly. Technical documents verified September 2026: the 114 documents gone through in full in our published list — among them Stellantis 18-091-23 and S2008000112, Ford's 18V-735 dealer instructions and 26V-369 Part 573 report, GM N232395300, Volkswagen 01-21-09 and recall 24V-110, Honda A15-010 and Kia SC288 Rev 3.

Had a P0440 fixed by a cap, a software update, a recall or a new canister or tank — or talked out of one? Email [email protected] with the vehicle, mileage and outcome.