SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out the PCM KOEO self-
test.
6. If the DTCs retrieved are related to the concern, go to the PCM Diagnostic Trouble Code (DTC) Index to continue diagnostics.
7. If the concern remains after the inspection, determine the symptom. GO to Symptom Chart.
PCM Diagnostics Trouble Code (DTC) Index
a
As small as 1.02 mm (0.040 in).
Symptom Chart
Pinpoint Tests
NOTE: Reinstall or install new evaporative emission hose clamps removed or damaged during testing procedures.
PINPOINT TEST A: DTC P0442 SMALL LEAK IN EVAP SYSTEM
NOTE: Condition P0442 DTC set: less than 0.625 kPa (2.5 inches H
2
O) bleed-up over 15 seconds at 75% fuel fill. Vapor generation limit: more than 0.625 kPa (2.5
inches H
2
O) over 120 seconds.
DTC Description Source Action
P0442
Small Leak Detected in EVAP System
a
PCM GO to Pinpoint Test A.
P0457 Cap Off PCM GO to Pinpoint Test A.
P0456 Very Small Leak Detected in EVAP System PCM GO to Pinpoint Test A.
P0455 Major Leak or no Flow Detected PCM GO to Pinpoint Test B.
P1443 Very Small or no Purge Flow Detected PCM GO to Pinpoint Test B.
P1450 Excessive Vacuum Detected in the Fuel Tank PCM GO to Pinpoint Test C.
— Any Other PCM DTC PCM REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
SYMPTOM CHART
Condition Possible Sources Action
Hissing sound when
removing fuel cap
Canister vent solenoid.
Evaporative emissions canisters.
Fuel vapor control valve tube assembly.
EVAP canister tube.
EVAP canister purge outlet tube.
GO to Pinpoint
Test D.
Excessive fuel odor Canister vent solenoid.
Evaporative emissions canisters.
Fuel vapor control valve tube assembly.
Evaporative emissions test port.
EVAP canister purge outlet tube.
GO to Pinpoint
Test E.
Slow fuel fill Restriction in the canister vent solenoid, dust filter, carbon canisters and
canister attachment hoses or vent tubing.
Restriction in the fuel fill hose or fuel fill pipe.
GO to Pinpoint
Test C.
Test Step Result / Action to Take
A1 VISUALLY INSPECT THE COMPONENTS FOR
SMALL LEAKS
Check for the presence of a fuel filler cap. Do not
tighten or check for correct installation at this time.
Verify the canister vent solenoid is correctly seated
on the EVAP canister.
Check for cut or loose connections to fuel vapor
hoses, tubes and connections in the following
locations:
EVAP canisters to EVAP canister purge valve
EVAP canister to fuel vapor vent valve
assembly
Check the fuel filler pipe for damage.
Is a concern with a hose, tube, connection or
valve visually evident?
Yes
REPAIR or INSTALL new components as necessary. GO to A2.
No
GO to A2.
A2 CHECK AT THE EVAP TEST PORT FOR SMALL
SYSTEM LEAKS
Disconnect and plug the evaporative emission return
tube at the intake manifold.
Complete the evaporative emission system leak test.
Refer to Evaporative Emission System Leak Test in
this section.
Does the system pass the leak test?
Yes
GO to A3.
No
GO to A4.
A3 VISUALLY INSPECT THE FUEL FILLER CAP
2004 Freestar/Monterey Workshop Manual
http://www.fordtechservice.dealerconnection.com/pubs/content/~WS4W/~MUS~LEN/20/
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