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Pinpoint Test A: DTC P0442 Small Leak In EVAP System

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
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.
  1. 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 filler pipe recirculation tube.
      • EVAP canister to EVAP canister purge valve
      • EVAP canister to fuel vapor vent valve assembly
      • Fuel vapor valve tube assembly to fuel tank
    • Check the fuel filler pipe and fuel filler cap seal surface for damage.
    • Check fuel pump and sender flange and connections.
    • Is a concern with a hose, tube, connection or valve visually evident? 
    1. Yes  : REPAIR or INSTALL new components as necessary. GO to A2.
    2. No  : GO to A2.
  2. 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 .
    • Does the system pass the leak test? 
    1. Yes  : GO to A3.
    2. No  : GO to  A4.
  3. A3 VISUALLY INSPECT THE FUEL FILLER CAP 
    • Visually inspect the fuel filler cap for damage.
    • Is the fuel filler cap damaged? 
    1. Yes  : INSTALL a new fuel filler cap. GO to A4.
    2. No  : GO to A4.
  4. A4 CHECK FOR SMALL LEAKS AT THE FUEL FILLER CAP AND EVAP TEST PORT 
    • Connect the Evaporative Emission System Tester to the fuel filler pipe.
    • Key in ON position.
    • Close the canister vent solenoid. Refer to CANISTER VENT SOLENOID CLOSING PROCEDURE .
    • Pressurize the EVAP system to 3.48 kPa (14 inches H 2 O).
    • Using the ultrasonic leak detector, check the fuel filler cap and EVAP test port for leaks.
    • Is a leak detected? 
    1. Yes  : REPAIR or INSTALL new components as necessary. GO to A5.
    2. No  : INSTALL the fuel filler cap. CARRY OUT the evaporative emission system leak test. Refer to EVAPORATIVE EMISSION SYSTEM LEAK TEST . If the system passes the leak test, CARRY OUT the evaporative emissions repair verification drive cycle. REFER to EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE .
  5. A5 CHECK FOR CONCERN OTHER THAN THE FUEL FILLER CAP 
    • Refer to previous test results.
    • Did the system pass the evaporative emission system leak test carried out in Step A2? 
    1. Yes  : CARRY OUT the evaporative emission system leak test. Refer to EVAPORATIVE EMISSION SYSTEM LEAK TEST . If the system passes the leak test, CARRY OUT the evaporative emission repair verification drive cycle. REFER to EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE .
    2. No  : INSTALL the fuel filler cap. GO to A6.
  6. A6 CHECK FOR SMALL LEAK WITH TESTER SET AT FILL POSITION 
    • Connect the Evaporative Emission System Tester to the EVAP test port.
    • Key in ON position.
    • Close the canister vent solenoid. Refer to CANISTER VENT SOLENOID CLOSING PROCEDURE .
    • Turn the selector on the Evaporative Emission System Tester to the FILL position.
    • Pressurize the EVAP system to 3.48 kPa (14 inches H 2 O).
    • Does the pressure on the EVAP system hold between 3.43 kPa and 3.53 kPa (13.80 inches and 14.20 inches H 2  O)? 
    1. Yes  : GO to A7.
    2. No  : DISCONTINUE pressurizing the system. GO to A8.
  7. A7 CHECK FOR LEAKS IN THE COMPLETE EVAP SYSTEM 
    • Connect the Evaporative Emission System Tester to the EVAP test port.
    • Key in ON position.
    • Close the canister vent solenoid. Refer to CANISTER VENT SOLENOID CLOSING PROCEDURE .
    • Pressurize the EVAP system to 3.48 kPa (14 inches H 2 O).
    • Using the ultrasonic leak detector, check the following EVAP system locations:
      • EVAP return tube to EVAP canister purge valve (vapor line) connections.
      • EVAP canister purge valve to EVAP canister - canister vent solenoid assembly
      • EVAP canister - canister vent solenoid assembly to fuel tank
      • Fuel filler cap and fuel filler pipe
      • Evaporator vapor line connections at fuel tank
    • Is a leak detected at EVAP return tube, EVAP canister purge outlet tube or EVAP canister tube or associated hose? 
    1. Yes  : REPAIR or INSTALL new components as necessary. CARRY OUT the evaporative emission system leak test. Refer to EVAPORATIVE EMISSION SYSTEM LEAK TEST . If the system passes the leak test, CARRY OUT the evaporative emissions repair verification drive cycle. REFER to EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE .
    2. No  : DISCONTINUE pressurizing the system. GO to A8.
  8. A8 CHECK FOR SMALL LEAK FROM THE EVAP RETURN TUBE TO THE EVAP CANISTER 
    • Disconnect the fuel tank vapor tube at the fuel tank locations. Plug the openings in the tubes.
    • Connect the Evaporative Emission System Tester to the EVAP test port.
    • Key in ON position.
    • Close the canister vent solenoid. Refer to CANISTER VENT SOLENOID CLOSING PROCEDURE .
    • Pressurize the EVAP system to 3.48 kPa (14 inches H2 O).
    • Using the ultrasonic leak detector, check the EVAP system from the intake manifold to the EVAP canister vent solenoid.
    • Is a leak detected? 
    1. Yes  : REPAIR or INSTALL new components as necessary. REPEAT Step A6 to verify the repair. GO to A9.
    2. No  : OPEN the canister vent solenoid. GO to A9.
  9. A9 CHECK FOR SMALL LEAK BETWEEN FUEL TANK VAPOR TUBE AND FUEL TANK FILLER PIPE 
    • Connect the Evaporative Emission System Tester to the fuel filler pipe.
    • Plug the FLVV and Fuel Vapor Vent valve ports on the fuel tank.
    • Turn the Evaporative Emission System Tester selector to the FILL position.
    • Pressurize the EVAP system to 3.48 kPa (14 inches H2 O).
    • Using the ultrasonic leak detector, check the fuel filler pipe connection to the fuel tank for leaks. Check the fuel tank pump and sender connections. Check all fuel tank welded joints.
    • Is a leak detected? 
    1. Yes  : REPAIR or INSTALL new components as necessary. GO to A10
    2. No  : GO to A10.
  10. A10 CHECK EVAP SYSTEM AT FUEL FILLER PIPE 
    1. Yes  : RESTORE the system to normal operation. CARRY OUT the evaporative emission system leak test. Refer to EVAPORATIVE EMISSION SYSTEM LEAK TEST . If the system passes the leak test, CARRY OUT the evaporative emissions repair verification drive cycle. REFER to EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE .
    2. No  : GO to  A6.
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