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Article No.
02-20-7

10/14/02

DRIVEABILITY - MALFUNCTION INDICATOR LAMP
(MIL) ILLUMINATED - AND/OR DIAGNOSTIC
TROUBLE CODES (DTC'S) P0442, P0455, P0456, P0457

FORD:
2001 ESCAPE
2001-2002 WINDSTAR

Article 01-17-2 is being republished in its entirety to update the model year coverage.

This article applies to all 2001 Windstar, 2002 Windstar vehicles built before 2/3/2002 and 2001 Escape vehicles built before 6/6/2001.

ISSUE
Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated, and/or Diagnostic Trouble Codes (DTC's) P0442, P0455, P0456, P0457. This may be due to a small fuel vapor leak coming from the Fill Limit Vent Valve (FLVV) Over Pressure Relief (OPR) port area, of the Evaporative Emissions System (EVAP).

ACTION
For 2001-2002 Windstar, install a clamp (part number 1F2Z-9A064-AA) on the Over Pressure Relief portion of the Fuel Tank Fill Limit Vent Valve.

For the 2001 Escape built before June 6, 2001, install a clamp (part number W525901-S300) on the end of the Over Pressure Relief hose.

Refer to the following Service Procedure for details.

SERVICE PROCEDURE
NOTE:
THE LIKELY CODE RELATED TO THE FUEL TANK FILL LIMIT VENT VALVE OVER PRESSURE RELIEF VALVE IS P0442 (EVAP
CONTROL SYSTEM LEAK DETECTED SMALL LEAK). OTHER CODES THAT POSSIBLY MAY BE ACTIVATED ARE P0457 (EVAP
CONTROL SYSTEM FUEL LEAK FILLER CAP LOOSE/OFF), P0456 (EVAP CONTROL SYSTEM LEAK DETECTED VERY SMALL
LEAK), OR P0455 (EVAP CONTROL SYSTEM LEAK DETECTED NO PURGE FLOW OR LARGE LEAK).

Procedure for 2001-2002 Windstar:
1. Perform a leak test of the EVAP system.
NOTE:
IT IS RECOMMENDED TO DIAGNOSE THE LEAK WITH A ROTUNDA SMOKE LEAK DETECTION MACHINE (MODEL 218-00001) OR EQUIVALENT. IF THE (FLVV) (OPR) IS LEAKING, SMOKE IS TYPICALLY SEEN AT THE REAR TOP LEFT OF THE FUEL TANK. THE LEAK IS OFTEN REPORTED TO DISAPPEAR ONCE THE FUEL TANK IS LOOSENED.

2. Remove the fuel tank as outlined in the Workshop Manual Section 310-01.


3. Install a Clamp 1F2Z-9A064-AA on the (OPR) portion of the (FLVV) using a Rotunda Keystone Clamp Installer (part number T63P-9171-A), see Figure 1.

4. Re-install the fuel tank per Workshop Manual.

5. Leak test the (EVAP) system to confirm all leaks have been repaired.

6. Using NGS or WDS tool clear the (DTC's) as related to the repair.

Procedure for the 2001 Escape:
NOTE
IT IS RECOMMENDED TO DIAGNOSE THE LEAK WITH A ROTUNDA SMOKE LEAK DETECTION MACHINE (MODEL 218-00001) OR EQUIVALENT.

1. Perform a leak test of the EVAP system. If the (FLVV) (OPR) is leaking, smoke is typically seen coming from the (OPR) hose.
NOTE
THE FUEL TANK DOES NOT NEED TO BE REMOVED FOR THIS REPAIR.

2. To repair the leak, bend the last 3/4 to 1 inch of the end of the (OPR) hose in half (9G271) and place the Clamp (W525901-S300) over the end of the hose and tighten it to stop the leak.

3. Leak test the (EVAP) system to confirm all leaks have been repaired.

4. Using the NGS or WDS tool clear the (DTC's) as related to the repair.

PART NUMBER - PART NAME
1F2Z-9A064-AA - Clamp - Windstar Procedure
W525901-S300 - Clamp - Escape Procedure

OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-17-2
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage

OPERATION: 022007B
DESCRIPTION: Install Clamp On the Over Pressure Relief Hose - Escape Only
TIME: 0.8 Hr.

DEALER CODING
BASIC PART NO.: 9002
CONDITION CODE: 42

OASIS CODES: 404000, 698298

 

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Bulletin No: 01-021/01R

Last Issued: 12/21/2001

Subject:
MIL ILLUMINATION WITH DTCS P0442, P0455, P0456, P0457

BULLETIN NOTE
This bulletin supercedes 01-021/01, issued 12/10/01. The REPAIR PROCEDURE has been changed.

APPLICABLE MODEL(S)/VINs
All 2001 Tributes built prior to June 6, 2001.

DESCRIPTION
Some vehicles may exhibit Malfunction Indicator Lamp (MIL) illumination and/or Diagnostic Trouble Codes (DTC) P0442, P0455, P0456, P0457 stored in memory. This may be caused by a small fuel vapor leak coming from the Fuel Vapor Vent valve (FW), located at the top of the fuel tank.

Customers having this concern should have their vehicle repaired using the following procedure.

REPAIR PROCEDURE
1. Verify customer concern.

2. Perform leak test of EVAP system according to Workshop Manual (section 01-01-301 EVAPORATIVE EMISSION SYSTEM LEAK TEST). Use Mazda Evaporative Emission Tester (part number 134-01042) with adaptors, part number 134-01034, or part number 134-01043 (GM dualed dealers only) or equivalent. Refer to SST bulletin number 007/01.
- If leak is found at FW vent hose, proceed to STEP 3.
- If leak is not found at FW vent hose, continue diagnosing EVAP system and repair any leaks as necessary.
Note:
If performing leak test with a smoke machine equipped leak tester, and FW valve is leaking, smoke will be visible coming from the open end of the FW valve hose.

3. Remove rear seat cushion according to Workshop Manual (section 09-13 SEATS).

4. Remove fuel pump module access cover according to the Workshop Manual (section 01-14 FUEL PUMP MODULE).

5. Pull loose end of FW vent hose into fuel pump module access opening.


6. Bend in half approximately one inch of loose end of FW valve hose and place clamp over folded end and tighten.


7. Return FW valve hose back to its original position.

8. Perform leak test using evaporative tester to confirm repair.

9. Using WDS, clear DTCs related to this repair.

10. Using WDS, perform EVAP test to verify repair.

PART(S) INFORMATION
9XF2-59-01X0 - Clamp - Qty. 1

WARRANTY INFORMATION
Warranty Type: A
Symptom Code: 62
Damage Code: 9B
Part Number Main Cause: 5555-01-013A **
Quantity: 1
Operation Number / Labor Hours: YY271XRX / 0.8
**: Part number main cause 5555-01-013A is for reimbursement of clamp.

Note:
This information applies to verified customer complaints on vehicles covered under normal warranty. Refer to the SRT microfiche for warranty term information.