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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 428 (Fuel System) >> Diagnosis And Testing >> Evaporative Emissions >> Pinpoint Tests >> Pinpoint Test A: DTC P0442 Small Leak In EVAP System, DTC P0456 Very Small Leak In EVAP System, DTC P0457 Missing Or Leaking Fuel Filler Cap

Pinpoint Test A: DTC P0442 Small Leak In EVAP System, DTC P0456 Very Small Leak In EVAP System, DTC P0457 Missing Or Leaking Fuel Filler Cap

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  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 hose is correctly seated on the canister vent solenoid.
    • Check for cut or loose connections to fuel vapor hoses, tubes and connections in the following locations:
      • EVAP canister to EVAP canister purge valve
      • EVAP canister to fuel vapor vent valve assembly
      • fuel vapor control valve tube assembly to fuel tank
      • fuel vapor control valve
    • Check the fuel filler pipe for damage.
    • 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 Leak 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 H2O).
    • 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 pinpoint test 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 Leak 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 Leak Tester to the FILL position.
    • Pressurize the EVAP system to 3.48 kPa (14 inches H2O).
    • Does the pressure on the EVAP system hold between 3.43 kPa and 3.53 kPa (13.80 inches and 14.20 inches H2O)? 
      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 Leak 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 H2O).
    • Using the ultrasonic leak detector, check the following EVAP system locations:
      • EVAP return tube to EVAP canister purge valve
      • 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 tube
    • 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 FUEL VAPOR CONTROL VALVE TUBE 
    • Disconnect the fuel vapor control valve tube assembly from the under vehicle fuel supply and vapor tube assembly. Plug the open end of the under vehicle fuel supply and vapor tube assembly.
      Fig 1: Identifying Fuel Vapor Control Valve Tube
      G03202072Courtesy of FORD MOTOR CO.
    • Connect the Evaporative Emission System Leak Tester to the EVAP test port.
    • Pressurize the EVAP system to 3.48 kPa (14 inches H2O).
    • Using the ultrasonic leak detector, check the EVAP system from the intake manifold to the plugged end of the under vehicle fuel supply and vapor tube assembly.
    • 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  : GO to A9.
  9. A9 CHECK FOR SMALL LEAK BETWEEN EVAP CANISTER AND FUEL TANK FILLER PIPE 
    • Connect the Evaporative Emission System Leak Tester to the fuel filler pipe.
    • Transfer the plug from the under-vehicle fuel supply and vapor tube assembly to the fuel vapor control valve tube.
    • Turn the Evaporative Emission System Leak Tester selector to the FILL position.
    • 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 H2O).
    • Using the ultrasonic leak detector, check the fuel vapor control valve tube to the fuel tank for leaks. Check the fuel tank pressure sensor, fuel vapor control valve tube and the fuel filler pipe. Check tubes from the fuel tank to the EVAP canister and the canister vent solenoid.
    • 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 
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