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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
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