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Pinpoint Test A: DTC P0442 Small Leak In EVAP System

WARNING: This page is about a different car, the 2004 Mercury Monterey and 2004 Ford Freestar. 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 H2 O) bleed-up over 15 seconds at 75% fuel fill. Vapor generation limit: more than 0.625 kPa (2.5 inches H2 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 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.

  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? 

    Yes 

    GO to A3.

    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? 

    Yes 

    INSTALL a new fuel filler cap. GO to A4.

    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 H2 O).
    • Using the ultrasonic leak detector, check the fuel filler cap and EVAP test port for leaks.
    • Is a leak detected? 

    Yes 

    REPAIR or INSTALL new components as necessary. GO to A5.

    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? 

    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 .

    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 H2 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)? 

    Yes 

    GO to A7.

    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 H2 O).
    • 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 canisters - canister vent solenoid assembly to fuel tank
      • fuel filler cap and fuel filler pipe
    • Is a leak detected at EVAP return tube, EVAP canister purge outlet tube or EVAP canister tube or associated hose? 

    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 .

    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 (9G332) at the fuel vapor tee. Plug the opening in the tee.
    • 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 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? 

    Yes 

    REPAIR or INSTALL new components as necessary. REPEAT Step A9 to verify the repair. GO to A9.

    No 

    OPEN the canister vent solenoid. GO to A9.

  9. A9 CHECK FOR SMALL LEAK BETWEEN FUEL TANK VAPOR TUBE (9C047) AND FUEL TANK FILLER PIPE 
    • Connect the Evaporative Emission System Leak Tester to the fuel filler pipe.
    • Transfer the plug from the fuel vapor tee to the fuel tank vapor tube (9C047).
    • Turn the Evaporative Emission System Leak 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 tank vapor tube to the fuel tank for leaks. Check the fuel tank pressure sensor, fuel tank vapor tube and the fuel filler pipe.
    • Is a leak detected? 

    Yes 

    REPAIR or INSTALL new components as necessary. GO to A10.

    No 

    GO to A10.

  10. A10 CHECK EVAP SYSTEM AT FUEL FILLER PIPE 
    • Reconnect the fuel tank vapor tube (9C047) to the fuel vapor tee.
    • Complete the evaporative emission system leak test. Refer to EVAPORATIVE EMISSION SYSTEM LEAK TEST .
    • Does the EVAP system pass the leak test? 

    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 .

    No 

    GO to A6.

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