EVAP leak woes...Help!

TLDR: 2013 Mazda5 Automatic with P0442 small leak evap code is now a P0455 large leak evap code. Have already replaced gas cap and vapor canister vent valve.


Hello, I purchased my 2013 Mazda5 touring with about 50k miles on it a year ago and have been fairly happy with it so far.

One issue I had right off the bat was certain gas pumps would not auto shut off when full and this caused gas to spray out and down the side of my car a couple times before I started monitoring and manually stopping the pump before the tank was full (still do this every time I fill up).

About 6 months in I got my first p0442 small EVAP leak check engine light. I did some research here and ended up replacing the Dorman 911-711 Vapor Canister Vent Valve under the car, after resetting the CEL it was good for awhile then came back after a few months of driving. This has been the routine of resetting the CEL and it coming back since I made that repair with no other noticeable impact on driving.

This last time the CEL came back I went to reset it and saw that it is now both p0442 (small leak) but also p0455 (EVAP large leak). This was alarming to me especially as my registration is due soon and I will have to pass an emissions test.

Any recommendations for what I should try next? I do have an extended powertrain warranty on the car still, but I don’t think it will cover emissions issues. The fact that gas will spray out of the gas tank without shutting off when it’s full could point to possible fuel filler neck issues? This gas overflow did happen once again after I replaced the vapor canister vent valve, so I don’t know if I should go ahead and replace this again. I suppose I can bite the bullet and get a smoke test if that is the best option at this point. Thank you for any help you can give!
 
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Smoke test. You have a leak and it could be anywhere. All the hoses and grommets and connections are all aged rubber and plastic and the leak can be anywhere.

Lucky for you, it's now a BIG leak...so should be easy to find with a smoke test.
 
...as an aside:

If you have to drop the tank, you may as well replace the fuel pump, sending unit, and all the seals, valves, hoses and so forth since it'll be far easier when the tank is down.
 

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