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TSB 08-5-5

03/17/08

SLOW FUEL FILL AND/OR DTC P0451

FORD:
2005-2008 Escape Hybrid, Escape

MERCURY:
2005-2008 Mariner
2006-2008 Mariner Hybrid

This article supersedes TSB 07-25-7 to update the Title and Service Procedure.

ISSUE
Some 2005-2008 Escape, Escape Hybrid, Mariner and 2006-2008 Mariner Hybrid vehicles may exhibit a slow fuel fill concern or a malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0451 present. The condition may be caused by water/moisture or other contamination entering the fuel filler vent line and then freezing and/or causing a blockage.

ACTION
Follow the Service Procedure steps to correct the condition by relocating the fuel filler vent line.

SERVICE PROCEDURE
When performing this procedure it is not necessary to:
^ Drain any fuel from the tank
^ Remove the stone shield from the filler pipe
^ Disconnect the filler pipe from the fuel tank

NOTE
ANY WATER/MOISTURE OR OBSTRUCTIONS IN THE EVAPORATIVE VENT SYSTEM MUST BE REMOVED.

1. With the vehicle in neutral, position it on a hoist.

2. Remove the left rear wheel.

3. Remove the fuel filler cap.

4. Remove the two (2) upper filler pipe mounting screws.

5. Remove the single lower filler pipe mounting screw.

6. Carefully pull the upper end of the filler pipe away from the inner wheel well to gain access to the vent line.

7. Cut any tape or plastic straps holding the black plastic convoluted vent line to the filler pipe or underbody.

8. Pull the black plastic convoluted vent line underneath the vehicle.

9. Remove the vent line from the dust separator attached to the canister assembly and clear out the line using compressed air.

10. Inspect the dust separator for water/moisture or any obstruction. If water/moisture or obstructions are present follow Workshop Manual (WSM), Section 310-00 pinpoint test A. If no water/moisture or obstructions are present reattach vent line to dust separator and continue to next step.

11. Remove but do not discard the spider screen (vent cap) from the end of the vent line.

12. Measuring from the open end of the vent line, cut off and discard the last 13" (35 cm).

13. Reinstall the spider screen (vent cap) in the vent line.

14. Route the shortened vent line and spider screen (vent cap) as shown in Figure 1.


15. Push the spider screen (vent cap) at least 2" (50 mm) into the open subframe and body section alignment hole.

16. Secure the vent line to the fuel tank strap with a plastic tie strap.

17. Reposition the filler pipe into its original position.

18. Install the lower filler pipe mounting screw and tighten to 89 lb-in (10 N.m).

19. Install the two (2) upper filler pipe mounting screws and tighten to 27 lb-in (3 N.m).

20. Install the fuel filler cap.

21. Reinstall the wheel and tighten to 98 lb-ft (133 N.m).

22. Lower the vehicle from the hoist.

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

OPERATION
DESCRIPTION
TIME
080505A2005-2008 Escape, Escape Hybrid And Mariner, 2006-2008 Mariner Hybrid: Relocate Fuel Filler Vent Hose. Includes Time to Remove Left Rear Wheel, Fuel Cap And Partially Remove The Fuel Filler Pipe And Shield (Do Not Use With 9030A)
0.7 Hr.​
DEALER CODING
BASIC PART NO.
CONDITION CODE
9A089
55​
 

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Bulletin No.: 01-028/08

Last Issue: 04/16/2008

Subject:
COLD CLIMATE SLOW FUEL FILL - DTC P0451

BULLETIN NOTE
This bulletin supersedes the previous bulletin 01-034/07, issued on 08/03/07. The REPAIR PROCEDURE information has been revised.

APPLICABLE MODEL(S)/VINs
2005-2006 and 2008 Tribute
2008 Tribute Hybrid

DESCRIPTION
Some vehicles may exhibit a slow fuel fill concern during winter/freezing conditions, or a malfunction indicator lamp (MIL) on with Diagnostic Trouble Code (DTC) P0451 present. The condition may be caused by water/ moisture entering the fuel filler vent line, then freezing.

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

REPAIR PROCEDURE
NOTE:
When performing this procedure (unless it becomes necessary to follow the pinpoint test) it is NOT necessary to:
^ Drain any fuel from the fuel tank
^ Remove the stone shield from the filler pipe
^ Disconnect the filler pipe from the fuel tank

NOTE:
ANY WATER/MOISTURE OR OBSTRUCTIONS IN THE EVAP VENT SYSTEM MUST BE REMOVED.

1. Verify customer concern.

2. With vehicle in neutral, safely position it on a hoist.

3. Remove fuel filler cap.

4. Remove two (2) upper filler pipe mounting screws. filler pipe mounting screws.


5. Lift vehicle on hoist.

6. Remove left rear wheel.

7. Remove one (1) lower filler pipe mounting screw.


8. Carefully pull upper end of filler pipe cover away from inner wheel well to gain access to vent line.


9. Cut any tape or plastic tie straps holding black plastic convoluted vent line to filler pipe or underbody.

10. Pull black plastic convoluted vent line underneath vehicle.


11. Remove the vent line from the dust separator attached to the canister assembly and clear out the line using compressed air.

12. Inspect the dust separator for water/moisture or any obstruction.
- If water/moisture or obstructions are present, proceed to the "Pinpoint Test: Slow to Fuel" below.
- If no water/moisture or obstructions are present, reattach vent line to dust separator and continue to Step 13.

PINPOINT TEST: SLOW TO FILL
Normal Operation
Under normal operation, fuel should flow at a steady rate through the fuel tank filler pipe into the fuel tank. As fuel enters the fuel tank, air is vented through the filler pipe or the on-board refueling vapor recovery (ORVR) system.

This pinpoint test is intended to diagnose the following:
^ Fuel tank filler pipe vent tube (if equipped)
^ Fuel tank filler pipe
^ Evaporative emissions (EVAP) system
^ Fuel tank level shut-off valve (part of the fuel tank)
^ Fuel tank

Test Step
Result/Action to Take
A1 CARRY OUT INSPECTION AND VERIFICATION
  • Carry out inspection and verification.[/*]
  • Was the cause of the concern found?[/*]
Yes
REPAIR or INSTALL new components to correct the concern.
No
Go to A2
A2 CHECK THE SYSTEM FOR ANY EVAPORATIVE EMISSION (EVAP) DTCs
  • Connect the scan tool.[/*]
  • Check the system for any of the following EVAP DTCs: P0446, P0451, P0452, P0453, P0454, P1443, P1450, P1451 AND P260F.[/*]
  • Are any of these DTCs present?[/*]
Yes
REFER to DTC diagnostic section in Workshop Manual to diagnose and repair the EVAP system.
No
Go to A3
A3 MONITOR THE FUEL TANK PRESSURE (FTP) WHILE FILLING THE FUEL TANK
  • Monitor the fuel tank pressure (FTP) reference value while filling the fuel tank. Refer to DTC diagnostic section in Workshop Manual.[/*]
  • Is FTP within specification?[/*]
Yes
Go to A5
No
Go to A4
A4 MONITOR THE FTP WHILE FILLING THE FUEL TANK WITH THE EVAP SYSTEM DISCONNECTED
  • Disconnect the fuel tank-to-EVAP canister quick connect coupling at the EVAP cannister. REFER to "Quick Connect Coupling" in this section.[/*]
  • Monitor the FTP reference value while filling the fuel tank. Refer to DTC diagnostic section in Workshop Manual.[/*]
  • Is FTP within specification?[/*]
Yes
INSPECT the EVAP system for blockage or restrictions. REPAIR the blockage or restriction. If the blockage or restriction cannot be repaired, INSTALL new EVAP system components.
No
Go to A5
A5 CHECK THE FUEL TANK FILLER PIPE ASSEMBLY FOR BLOCKAGE OR RESTRICTION
  • Remove the fuel tank filler pipe assembly according to the Workshop Manual (section 01-14 FUEL TANK FILLER PIPE REMOVAL/INSTALLATION).[/*]
  • Inspect the fuel tank filler pipe and fuel tank filler pipe vent tube (if equipped) for blockage or restriction.[/*]
  • Is the fuel tank filler pipe or fuel tank filler pipe vent tube (if equipped) blocked or restricted?[/*]
Yes
If possible, REPAIR the blockage or restriction. If the blockage or restriction cannot be repaired, INSTALL a new fuel tank filler pipe or fuel tank filler pipe vent tube.
No
Go to A6
A6 CHECK THE FUEL TANK LEVEL SHUTOFF VALVE
  • Inspect the fuel tank level shutoff valve for restriction or sticking.[/*]
  • Is the fuel tank level shutoff valve restricted or sticking?[/*]
Yes
If possible, REPAIR the restriction. If the restriction cannot be repaired, INSTALL a new fuel tank according to the Workshop Manual (section 01-14 FUEL TANK REMOVAL/INSTALLATION).
No
INSTALL a new fuel tank according to the Workshop Manual (section 01-14 FUEL TANK REMOVAL/INSTALLATION).
13. Remove, but do not discard spider screen (vent cap) from end of vent line.

14. Measuring from open end of vent line, cut off and discard the last 13" (35 cm).

15. Reinstall spider screen (vent cap) into vent line.

16. Route shortened vent line and spider screen (vent cap) into open subframe/body section alignment hole.


17. Push spider screen (vent cap) at least 2" (50 mm) into hole.


18. Secure vent line to fuel tank strap with a plastic tie strap.

19. Reposition filler pipe into its original position.

20. Reinstall one (1) lower filler pipe mounting screw.
Tightening Torque: 89 lb-in (10 Nm)

21. Reinstall left rear wheel.
Tightening Torque: 98 lb-ft (133 Nm)

22. Lower vehicle on hoist.

23. Reinstall two (2) upper filler pipe mounting screws.
Tightening Torque: 27 lb-in (3 Nm)

24. Reinstall fuel filler cap.

25. Verify repair.

WARRANTY INFORMATION
NOTE:
^ This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair.
^ This repair will be covered under Mazda's New Vehicle Limited Warranty term.
^ Additional diagnostic time cannot be claimed for this repair.

Warranty Type
A​
Symptom Code
64​
Damage Code
93​
Part Number Main Cause
5555-07-017A​
Quantity
0​
Operation Number / Labor Hours:
YY481XRX / 0.7 Hrs​
 
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