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TSB 08-26-10

01/05/09

DIFFICULT TO DIAGNOSE EVAP DTCS P0442, P0455,
P0456, P0457 - BUILT ON OR BEFORE 8/1/2008

FORD:
2009 Escape Hybrid, Escape

MERCURY:
2009 Mariner Hybrid, Mariner

ISSUE
Some 2009 Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles built on or before 8/1/2008 may exhibit difficult to diagnose Evaporative Emission (EVAP) system diagnostic trouble codes (DTCs) P0442, P0455, P0456 and P0457 due to rolled filler neck 0-ring.

ACTION
Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE
NOTE
THIS MESSAGE ONLY APPLIES TO VEHICLES WITH EVAP DTCS P0442, P0455, P0456, P0457. PERFORM NORMAL POWERTRAIN CONTROLS/EMISSIONS DIAGNOSIS (PC/ED) DIAGNOSTICS FOR ALL OTHER CODES.

  1. Using Integrated Diagnostic System (IDS), version 58.7 with patch 10 or higher, access the IDS EVAP test by selecting Toolbox/Powertrain/Fuel/EVAP test.
    NOTE
    IDS EVAP LEAK TEST SHOULD BE USED BEFORE AND AFTER ANY EVAP RELATED REPAIR.

    [/*]
  2. Begin the IDS EVAP test by following the IDS screen prompts, ensuring all necessary parameters have been met, and continue test until results have been provided.
    • Test passed - clear the DTCs, repeat self test, and return vehicle to customer.[/*]
    • Test failed - go to Step 3.[/*]
    [/*]
  3. The leak may be due to debris like sand or dust on the Capless door seal in the fuel filler neck. Insert and remove supplemental refueling adapter (SRA) funnel, or a standard unleaded refueling nozzle, five (5) times to cycle the Capless fuel fill door. Refer to owner guide for in vehicle SRA location. You may also use short bursts of low pressure shop air on the Capless fuel door seal to clear debris. Run IDS EVAP leak test again.
    • Test passed - clear the DTCs, repeat self test, and return vehicle to customer.[/*]
    • Test failed - go to Step 4.[/*]
    [/*]
  4. Connect the Rotunda Vacutec Smoke Machine (or equivalent) to the vehicle and run the leak detection smoke test. Refer to the PC/ED Pinpoint Test (PPT) HX, Workshop Manual (WSM) Section 303-13, and machine manufacturer's instructions.

    [/*]
  5. Inspect EVAP hoses and connections, EVAP canister, EVAP canister vent solenoid, fuel vapor tube assembly including fuel tank pressure sensor, fuel tank, fuel tank gasket, filler pipe, and Capless fuel fill door while pulsing the smoke machine at 15 second intervals.
    • No leak found - go to Step 6.[/*]
    • Leak found - repair per applicable WSM section. Run IDS EVAP leak test again.
      1. Test passed - clear the DTCs, repeat self test, and return vehicle to customer.[/*]
      2. Test failed - go to Step 6.[/*]
      [/*]
    [/*]
  6. The smoke test may not show a leak from the Capless fuel fill pipe opening when smoke is introduced through the Canister Purge Valve (CPV) vapor line. Access the fuel pump flange under the floor pan behind the driver's seat and disconnect the Fuel Tank Filler pipe recirculation tube from the top of the fuel pump flange. Introduce smoke through the recirculation tube and watch for smoke around and/or through the fuel fill pipe refuel opening.
    • No leak found - stop - refer to PC/ED PPT HX and continue with normal diagnostics.[/*]
    • Leak found - replace filler neck. Run IDS EVAP leak test again.
      1. Test Passed - clear the DTCs, repeat self test, and return vehicle to customer.[/*]
      2. Test Failed - Refer to PC/ED PPT HX and continue with normal diagnostics.[/*]
      [/*]
    [/*]

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

PART NUMBER
PART NAME
9L8Z-9034-AFill Pipe Assembly
OPERATION
DESCRIPTION
TIME
MT082610Use SLTS Operations If Available; Claim Additional Diagnosis Or Labor Performed As Actual Time
Actual Time​
DEALER CODING
BASIC PART NO.
CONDITION CODE​
9034
D8​
 
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