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Reviving this old thread yet again as it's still relevant.

I took my faithful '03 XS to the dealer for his opinion on the p0442 code that is stopping me from passing inspection is NJ.

$130 + tax later he claims it is the Vent Valve on top of the fuel tank. From all the threads I've read, I didn't see anyone mention this valve as the cause. All threads point to the filler neck and other canister valves. Of course the fuel tank vent valve is the last thing anyone would want to replace as it's in the worst place possible; on top of the fuel tank. His cost estimate to replace this valve was over $1300. And that didn't cover, as he called it, "possible" breakage of rusted parts in the process of getting to the tank. I'm sure my exhaust system would be the first casualty.

I'm taking it to another dealer for a second opinion. Then I'll decide what to do. I may try to check the filler neck check as was mentioned here as this seems the most plausible, all things considered.

to be continued.......
Eager to hear if you got any better news from the second dealer.

I have a 2004 Forester XS that received a similar diagnosis from the Sube dealer. Codes P0442, P0457, and P0519 were found. Smoke was seen at top of gas tank during smoke test.

Dealer says gas tank must be dropped ($525+) to determine exactly where leak is. At that point he recommends replacing the gas tank and all associated valves -- total cost around $2k.

I have until the end of May, when next inspection due, to fix this. In spite of the dealer finding smoke at the gas tank, I'm going to check the filler neck to see if it's rusted out, in a last ditch effort.

Very frustrating because this car, which we bought new, only has 84k miles and runs/looks great. Given its age and the potential for other big ticket items, sadly, the end of the road may be approaching soon for it.
 

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I had the P0422 code for 6 months, and had searched several forums. I had already replaced the gas cap, with no luck. Today, i found one that addressed the issue I had - and sharing to the extent that it may help someone else. In the front engine compartment, there was a hose disconnected from a blue nipple. This has been noted on another forum as the cause for others to have the P0442 code. See pictures included below. The hose is just to the left of the center of engine, looking at it from the front top. If you follow the hose (on the bottom of the circular object in the 1st pic) you will find it connects to a blue nipple (2nd pic)- this was not attached. I reattached it.
 

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Eager to hear if you got any better news from the second dealer.
Actually, I didn't go to a second dealer, but to a trusted mechanic who I've used numerous times for other vehicles. I've had my fill of dealers for the moment.

He smoked the system and found a leak by the filler neck. He replaced the filler neck and the filler neck shutoff valve. He said he "didn't like the way the shutoff valve looked" so he replaced it too.

Having said that and having the old filler neck & shutoff valve to look at, I believe it was only the shutoff valve. I plan to plug off the filler neck connections and pressurize the assembly as soon as I get a chance. As like I said, I don't think it was the neck, not enough rust on it. But the mating surface of the neck flange & shutoff valve was very rusty and that may have been the leaking surface.

I did pressure test the shutoff valve and it leaked whether it was open or closed. More so in one position than the other, but leaked still the same.

The mechanic reset the code (p0442) and I'm driving it trying to reset the monitors. As I understand it, I can pass NJ inspection with one monitor in the "not ready" state. So I'll go to inspection as soon as I get them down to 1.

I won't list his price as costs are different everywhere you go, but it was significantly less than the dealer. Of course, the job was different too, so no real comparison anyway. It was 2 1/2 hrs labor/diagnosis and he used all Subaru parts. <-- so not cheap there.

edit: 4/25/19

So I passed NJ inspection. I had (1) monitor "not ready", the Evap monitor. That monitor refused to set no matter how I drove the car, stop&go, highway cruise, slow down/speed up, didn't matter. I put 800 miles on it and nothing I tried, did it. I read numerous threads & googles telling me what drive cycle would do it, nothing worked. But in NJ, they do not fail you if the Evap monitor is incomplete. That incomplete however is your (1) monitor "grace". You can't have anyone else incomplete (2001 & up). But you must have the O2 & the Converter monitors set as those are the ones they are really interested in. I got those to set in a 15 min loop from work with 10 min of highway at 50mph and 5 min of ramps & stoplights. So I'm good for 2 years & the Evap monitor still isn't set. lol

edit: 5/1/19 - added some pictures.
 

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