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FUEL FILL INLET ERROR MESSAGE

81K views 32 replies 16 participants last post by  backroad101 
#1 ·
2010 Escape 4cyl, 40,000 mi. At about 36,500 mi. the message center would warn me to "check the fuel fill inlet" after filling up. Of course, after checking it, it seemed fine. I would shove the funnel provided in the inlet, and after several driving cycles the message would go away. In the manual, it states that multiple "check the fuel fill inlet" errors may cause the CEL to come on, and now it has. I had the code pulled and P0455 refers to an emmission problem, or simply checking the fuel cap is on tight. Obviousily there is no gas cap to check. Has anyone else gotten this message and found a solution? I could bring it to Ford and have them diagnose the problem, but hopefully someone out there knows the fix. I am certain the problem causing the CEL to come on is the fuel fill inlet, but I dont see anything in that area to check or reconnect or replace. Any Ford mechs out there know how to fix this?
 
#2 ·
This is the 'capless' fill system, right?
This should be covered by the emissions certification warranty. My guess is that the automatic mechanism is not working properly. As part of the emission control system, it should have the longer warranty just as a catalytic converter does.
IOW, take it to the dealer. All costs should be covered.

tom
 
#3 ·
This "check fuel fill inlet" happened to my 2009 Escape about four times and would reset after using the funnel. The fifth time it wouldn't go off and I took it to the dealer. They replaced the emissions cannister and purge solenoid. The parts listed were 9R3Z 9C985 B Cannister and a CX 2349 Valve assembly.
 
#5 ·
The work done on mine was under TSB 11-11-28 and was for Escapes built up to 3/4/2011.

Text of the TSB is:

11-11-28•MIL LAMP ON WITH DTCS P144A, P2196, P2198, P1450, P0455, P0456, AND/OR P0457 BUILT ON OR BEFORE 3/4/2011
Publication Date: November 18, 2011
FORD:
2010-2011 Fusion
2009-2011 EscapeMERCURY:
2010-2011 Milan
2009-2011 Mariner

This article supersedes TSB 11-3-22 to update the Title, Issue Statement, and Service Procedure. ISSUE:

Some 2009-2011 Escape, Mariner, 2010-2011 Fusion and Milan vehicles equipped with a 2.5L DOHC or 3.0L engine built on or before 3/4/2011 may exhibit a leaking/stuck under hood evaporative emission purge valve. This fault will turn on the malfunction indicator lamp (MIL) and set diagnostic trouble codes (DTC) P144A, P2196, P2198, P1450, P0455, P0456, and/or P0457.
ACTION:

Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE

1.Are any of the following DTCs P144A, P2196, P2198, P1450, P0455, P0456, and/or P0457 present?
1.No - Do not continue with this article.

2.Yes - Proceed to Step 2.

2.Remove the evaporative emission canister. Refer to Workshop Manual (WSM), Section 303-13. Inspect canister for liquid fuel by turning the canister over and watching for signs of liquid fuel exiting the canister. Are there any signs of liquid fuel present?
1.No - Proceed to Step 3.

2.Yes - Replace the evaporative emission canister. Refer to WSM, Section 303-13. Proceed to Step 3.

3.Are P0455, P0456, and/or P0457 the only DTCs present?
1.No - Refer to the WSM, Section 303-13 to locate the leak. Repair as needed.

2.Yes - Proceed to Step 4.

4.Perform IDS leak test, Refer to the Powertrain Control/Emission Diagnosis (PC/ED) pin point text HX. Did the leak test pass?
1.No - Refer to WSM, Section 303-13. to locate the leak. Repair as needed.

2.Yes - Replace the under hood evaporative emission canister purge valve. Refer to WSM, Section 303-13 and proceed to Step 5.

5.Clear stored DTCs.
PART NUMBERPART NAME9U5Z-9C915-HCanister Purge Valve9R3Z-9C985-BCanister (Escape/Mariner)9E5Z-9D653-CCanister (Fusion/Milan)

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty/ESP coverage limits/policies are not altered by a TSB. Warranty/ESP coverage limits are determined by the identified causal part and verified using the OASIS part coverage tool.
OPERATIONDESCRIPTIONTIME111128A2010-2011 Fusion And Milan: Check DTCs, Remove And Inspect The Evaporative Emission Canister, Replace If Necessary Includes Time To Perform The Evaporative Emission System Leak Test0.9 Hr.111128A2009-2011 Escape And Mariner: Check DTCs, Remove And Inspect The Evaporative Emission Canister, Replace If Necessary, Includes Time To Perform The Evaporative Emission System Leak Test1.0 Hr.111128B2010-2011 Fusion And Milan: Check DTCs, Remove And Inspect The Evaporative Emission Canister, Replace If Necessary, And Replace The Evaporative Emission Canister Purge Valve Includes Time To Perform The Evaporative Emission System Leak Test1.0 Hr.111128B2009-2011 Escape And Mariner: Check DTCs, Remove And Inspect The Evaporative Emission Canister, Replace If Necessary, And Replace The Evaporative Emission Canister Purge Valve Includes Time To Perform The Evaporative Emission System Leak Test1.2 Hrs.MT111128For Any Additional Diagnosis Or Repair Related to Pin Point Test HX Use SLTS Operations If Available Or Actual Time.Actual Time
DEALER CODING

BASIC PART NO.CONDITION CODE9C91542
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford or Lincoln dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.
Copyright © 2011 Ford Motor Company
 
#6 ·
Nice info, and note that the emissions warranty was mentioned. Give your dealer a call, or inspect your emissions warranty documentation for time/mileage limits to see if the part(s) is covered. I believe that the evaporative emissions control system is covered for 80,000 miles/10 years, but have been known to be ill informed a time or two.
tom
 
#7 ·
Saw on a tsb that to reset the fuel fill inlet, slowly insert and remove the funnel 5 times. I tried it when the fuel inlet warning message was on again and after driving a few miles, the message went away (CEL still on though). I may disconnect the battery to clear the CEL and then see if the message comes on again, and if so use the "funnel reset" to clear the message and then see if the CEL comes on again. I checked the emmissions warranty and it seems all emmission parts are covered 2yrs/24k for a performance defect and 3yrs/36k for a part defect (even though the bumper to bumper would cover them anyway). The 8yrs/80k emmission warranty coverage is only for certain parts:catalytic converters, electronic engine control unit (ECU), transmission control module (TCM), and any other onboard emissions diagnostic module, so I dont think that I am covered for this problem. If the check fuel fill inlet and the CEL come on again, I'll just bring it to the dealer. I have a Geico Mechanical Breakdown Warranty - 72 usd/yr (from day 1) and a 250usd deductible, good for 7 yrs or 100k.
 
#8 ·
Disconnected the battery this weekend (both leads) to clear the CEL and waited 45 mins or so, followed the manual for relearning the idle, then filled up, letting any gas in the hose flow out of the hose before slowly removing the nozzle. When finished filling up, I slowly inserted the fuel pump hose into the inlet (just far enough to open the inlet) 5 times to "reset" it. 3 days so far and the Check Fuel Fill inlet message has not come on. No CEL either.
 
#9 ·
My turn with this problem.

I got the Check Fuel Inlet Message 2 weeks ago today after getting gas the previous night. I jammed the plastic funnel thing in there a bunch of times. The message went away after a few drive cycles, but then returned followed by a CEL. I cleared the CEL and the messages stayed away for a couple days. I've gotten gas twice since the original message but I'm still getting the Check Fuel Fill Inlet Message no matter how many times I jam that stupid plastic funnel in there. It threw another CEL again two days ago with code P0457 (loose fuel cap). Since it keeps happening, I'm thinking sometimes is broken and it's not just debris in there.

(1) Is it OK to put off this repair until my next oil change (probably about 6-8 weeks from now)?
(2) What else could I damage by continuing to drive my E and clearing the CELs as I get them until my next service?
(3) I'm WAY out of warranty... Anybody had to pay for this repair out of pocket? How much is this going to hurt?
(4) Anybody completed this repair themselves? Is it easy enough? I'm mechanically inclined and have some tools.
(5) I typically fill my E two-clicks after the pump automatically shuts off. Do you think this could have led to this failure?
 
#10 ·
Mantruck101 said:
....(1) Is it OK to put off this repair until my next oil change (probably about 6-8 weeks from now)?
(2) What else could I damage by continuing to drive my E and clearing the CELs as I get them until my next service?
(3) I'm WAY out of warranty... Anybody had to pay for this repair out of pocket? How much is this going to hurt?
(4) Anybody completed this repair themselves? Is it easy enough? I'm mechanically inclined and have some tools.
(5) I typically fill my E two-clicks after the pump automatically shuts off. Do you think this could have led to this failure?
Hi Mantruck101,

Give the service manager at your local dealership a call; they'll be happy to help you out with your questions. They can also give you an accurate estimate of any potential repairs. Let us know how things go!

Crystal
 
#12 ·
Mantruck101 said:
My turn with this problem.

I got the Check Fuel Inlet Message 2 weeks ago today after getting gas the previous night. I jammed the plastic funnel thing in there a bunch of times. The message went away after a few drive cycles, but then returned followed by a CEL. I cleared the CEL and the messages stayed away for a couple days. I've gotten gas twice since the original message but I'm still getting the Check Fuel Fill Inlet Message no matter how many times I jam that stupid plastic funnel in there. It threw another CEL again two days ago with code P0457 (loose fuel cap). Since it keeps happening, I'm thinking sometimes is broken and it's not just debris in there.

(1) Is it OK to put off this repair until my next oil change (probably about 6-8 weeks from now)?
(2) What else could I damage by continuing to drive my E and clearing the CELs as I get them until my next service?
(3) I'm WAY out of warranty... Anybody had to pay for this repair out of pocket? How much is this going to hurt?
(4) Anybody completed this repair themselves? Is it easy enough? I'm mechanically inclined and have some tools.
(5) I typically fill my E two-clicks after the pump automatically shuts off. Do you think this could have led to this failure?
As a follow-up, I drove around with the CEL on for about 6 weeks. Today, the dealer wanted $97 to "diagnose the CEL." Like I told them, their computer confirmed that something was up with the evap valve. My Escape passed all the tests they ran (including a smoke test) so they were a bit stumped. In the end, they cleaned some debris out of said valve that they think was preventing it from closing completely (they said it was pretty dirty). No parts were replaced, the CEL was reset, and they didn't charge me anymore than that initial $97 for that job.

We'll see if this "fix" sticks or if my CEL comes back in a few drive cycles.
 
#13 ·
CEL came back two days later. :cuss: :cuss: :cuss: Here's an excerpt from my just-written post inanother related thread:

Mantruck101 said:
The CEL came back on Monday morning on my way to work, but without the CHECK FUEL FILL INLET message. This time, it was a P0458 code (gross leak or something according to my code reader).

I ordered a new charcoal canister and some related solenoid ($55, shipped from Tasca Parts) this week and hope to eliminate the problem by replacing those parts. After I ordered them, I got to thinking maybe the dealer did fix the problem by cleaning whatever they cleaned, but accidentally created a new one when re-assembling the system (i.e., forgetting to reconnect a vent hose perhaps?). I suspect this since I'm no longer getting the CHECK FUEL FILL INLET message and the code is different (P0455 vs P0458).
 
#14 ·
The saga continues... I had a different garage replace the EVAP canister and solenoid assembly this past Thursday. CEL came back on again with the same P0455 code on the way to work Friday morning. :cuss: :cuss: :cuss: So much for trying to diagnose it myself... So far I'm out $250 and it's still not fixed!

It's going back again to the dealer on July 3rd. They agreed to waive the diagnostic fee this time since they didn't diagnose the problem correctly the first time.
 
#15 ·
Having the same issue again. Fuel fill inlet warning came on again and so did the check engine light. The code it pulls is P0455 - large evap system leak. After it came on I again unhooked the battery to kill the code, but it came on again. Guess I will have to bring it into the dealer to get checked out. Its due for an inspection in a few months, and in NY you cant pass an inspection withe the cel on. I could try to replace parts as well, but I'll just use the Geico warranty I have - its still a 250 deductible, but at least that will be the max it will cost.
 
#16 ·
Am I the only one who hates this system? I find it much more finicky to use, poorer at retaining the pump nozzle, and simply more cumbersome than a good ol' cap...

tomw said:
This is the 'capless' fill system, right?
 
#17 ·
Yeah, it's the capless system. My Escape went back to the dealer on the July 3rd and they cleaned the same thing a second time. Not surprisingly, this didn't work and my CEL and the CHECK FUEL FILL INLET message returned the next day. I'm annoyed that they didn't try something new to fix the problem. (Isn't the definition of insanity something along the lines of repeating the same action and expecting a different result?) It essentially was a wasted trip for me (thank goodness they didn't charge me).

I called back and complained and the service manager stated that their next attempt would involve replacing the fuel filler neck assembly. He quoted me $298 for the part itself! I found it on Tascaparts.com for $85 (+$10) to ship it. Yeah... It came in earlier this week but I'm postponing having it installed. The Escape runs fine so why make another trip to the garage? I'm annoyed to say the least. I'm in about $250 in parts and this will be the 4th trip to a garage (2 already to the dealer and 1 to another garage) and the issue persists. It's going to wait until I'm due for another oil change for repair attempt #4.

I'm beginning to understand why people dump cars @ 100K miles. Even if this relatively cheap $85 part (plus labor) proves to be the fix, the headache of figuring it out has been extremely annoying.

Finally, I don't hate the capless system. Dealing with a gas cap is gross. I don't believe my problem is directly due to the capless design, but if it is, then maybe I hate it. Replacing a $15 gas cap sure would have been a lot easier.
 
#18 ·
Finally the problem is solved. After the CEL and check fuel fill inlet message came on again, I took it to the dealer. First they cleaned the fuel fill inlet and cleared the CEL. This lasted exactly 2 days before they both came on again. If you have this same problem, when you bring it to the dealer, insist they dont simply clean the inlet and send you on your way. It does not work and is a waste of your time. Brought it back again and they said they neeed to do a smoke test, but the tank was full, so I had to wait to use 1/2 tank of gas (the tank must be less than 1/2 full to do the test). They said the problem was the fuel fill inlet (no, really?) and the purge regulation valve. The valve should be easy to replace on your own - I believe it is in the engine compartment. The part number is 9u5z-9c915-h and cost 57.98 and 110.00 to install. If I had time, I would have replaced the part on my own before I brought the car in. Replace it yourself and save the money. The fuel fill inlet part number is cl8z - 9034-a. The inlet part and installation were covered under the emissions warranty (the warranty is up to 80k miles). To replace the inlet, the tank had to be less than 1/4 full. The total bill was $100 to diagnose, $57.98 for the valve, and $110 to install the valve ($278 total incld taxes). With those 2 parts replaced, I havent had any issues in the last 3 weeks. I do hate the capless system though.
 
#19 ·
Update on the cel...
 
#20 ·
CEL is still on in my Escape. I couldn't be bothered to take it back in before its next service as it runs fine. Like I mentioned previously, this will be the 4th attempt to fix it.

Its next oil change is about 1,000 miles and a month away so I'll give the dealer another chance to extinguish the CEL by changing the fuel filler pipe with the new one I ordered from Tasca Parts during that service.
 
#21 ·
I'm writing this post with the hope that my CEl has finally been fixed, but I'm not holding my breath.

My Escape went back to the dealer that tried to fix this problem twice already on Wednesday (2 Oct). The first two times they cleaned the fuel filler neck. If you read back, you'll recall that this dealer recommended replacing the fuel filler neck if the CEL came back (which it did).

I bought the fuel filler neck online from Tasca and as the dealer was busy when I pulled into the service bay. The service manager approached me and asked if I had the part with me. He then added, "yeah, we have a lot of those going bad." They replaced the part for $97 labor and I was on my way.

On Friday morning, the CEL returned on my way to work. I called the dealer and spoke directly with the service manager and bitched. He said to bring the Escape back ASAP. I told him I wanted it fixed for free and a free loaner. He agreed to the free loaner and said he would work with me on the repair costs given the inconvenience their inability to diagnose the problem has caused me.

I dropped the Escape off at 8AM last Saturday (5 Oct). I brought the 11-11-28 TSB with me and gave it to my service advisor (I also emailed it to the service manager AND wrote the TSB's number on the paperwork that would be given to the mechanic.) They gave me a free loaner and called me at 3PM to say they still couldn't figure it out. They wanted to keep the car over the weekend and I consented. I dropped by the dealer to pick up a few personal effects and talked directly to the mechanic working on it. He was visibly annoyed that he couldn't figured it out. For some reason, he thought the fuel filler neck I had given them was used (WTF? THEY unboxed it from the packaging). I mentioned the TSB and checking the underhood purge valve. The mechanic insisted he tested it and it was OK.

Fast forward to Monday (7 Oct) and they call me to say that they've found a "blockage" in a vent line from the EVAP charcoal canister thing. They cleaned it and told me to come pick it up.

Now it's Thursday (10 Oct) and the CEL comes back again while I'm driving to work. I took it back to the dealer again (REPAIR ATTEMPT #5) and am given a free loaner. I ask to speak with the service manager but he never shows because I think he's afraid of me at this point. This time, they finally replaced the underhood purge valve only after I again give them its part number, the TSB, and the symptoms. I picked it up yesterday morning (12 Oct) and the CEL is still out. I think they should refund my the initial $100 diagnostic fee since I'm the one that diagnosed the problem but... oh well.

If I make it an entire week without it returning, I think I'm finally in the clear. I told the service manager that I'll be taking it elsewhere if the problem returns and forwarding them the bill as I felt they've had enough opportunities to correctly diagnose and correct the problem. FWIW, the dealer did not charge me for 3/5 repair attempts and I was given a free loaner 3 times.

Hopefully this saves some other people some trouble. It cost me $500 and 6 trips to the garage (I had another garage replaced the EVAP charcoal canister). The saddest part is that the freakin' purge valve is like $32 from Tasca and a TSB exists for the exact problem I was having.
 
#23 ·
FordService said:
Mantruck101 said:
....(1) Is it OK to put off this repair until my next oil change (probably about 6-8 weeks from now)?
(2) What else could I damage by continuing to drive my E and clearing the CELs as I get them until my next service?
(3) I'm WAY out of warranty... Anybody had to pay for this repair out of pocket? How much is this going to hurt?
(4) Anybody completed this repair themselves? Is it easy enough? I'm mechanically inclined and have some tools.
(5) I typically fill my E two-clicks after the pump automatically shuts off. Do you think this could have led to this failure?
Hi Mantruck101,

Give the service manager at your local dealership a call; they'll be happy to help you out with your questions. They can also give you an accurate estimate of any potential repairs. Let us know how things go!

Crystal
WOW Crystal, if it were only that easy & simple. Usually the dealership knows zip and screws things up more then they were to begin with! This is a FACT!
 
#25 ·
I just ran into this problem the other day, 'check fuel filler inlet' displayed, followed by the check engine light.
Garage diagnosed and the code was P0457 'Evap leak'. they advised I have the filler neck replaced, but they can't guarantee that'll solve the problem. :? Im not sure what to do at this point.
 
#26 ·
Update: Took the Escape to a 'another' Ford dealership, they ran a diagnostic (even though it was already diagnosed at the other Dealer and the P0457 code came up), they insisted :roll: anyhow, they ended up replacing the Canister Purge valve (in the engine compartment), they said it was stuck open.
they cleared the code and I went on my way, I keep expecting the engine light to reappear though, as it's still running rough, has a flutter noise around the middle of the exhaust, so I'll be taking it back in. :wall:
 
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