Emissions - EVAP DTC's P0442/P0455/P0456/P0457

Bulletin No: 01-002/09

Last Issued: 1/20/2009

Subject:
DIFFICULT TO DIAGNOSE EVAP SYSTEM DTCS P0442, P0455, P0456 AND P0457

APPLICABLE MODEL(S)/VINS
2009 Tribute and Tribute Hybrid vehicles built on or before August 1, 2008

DESCRIPTION

Some 2009 Tribute and Tribute Hybrid vehicles built on or before 8/1/2008 may exhibit difficult to diagnose EVAP DTCs P0442, P0455, P0456 and P0457 due to a rolled filler neck O-ring.

- P0442 - Evaporative Emission (EVAP) System Leak Detected (small leak)

- P0455 - Evaporative Emission (EVAP) System Leak Detected (gross leak/no flow)

- P0456 - Evaporative Emission (EVAP) System Leak Detected (very small leak)

- P0457 - Evaporative Emission (EVAP) System Leak Detected (fuel cap loose/off)

Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

NOTE:
This message only applies to vehicles with EVAP DTCs P0442, P0455, P0456, P0457. Perform normal Workshop Manual diagnostics for all other codes.

1. Verify customer concern.

2. Using Integrated Diagnostic System (IDS), version 58.7 with patch 10 or higher, access the IDS EVAP test by selecting:

a. Toolbox

b. Powertrain

c. Fuel

d. EVAP test

NOTE:
^ IDS EVAP leak test should be used before and after any EVAP related repair. Refer to MS3 online service information or Workshop Manual section 01-01 - EVAPORATIVE EMISSION SYSTEM LEAK TEST - PHASE 1 - LEAK VERIFICATION.

3. 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 DTCs, repeat self test, and return vehicle to customer.

- Test Failed - Go to STEP 4.

4. Leak may be due to debris such as sand or dust on the Capless door seal in the fuel filler neck. Insert and remove the Supplemental Refueling Adapter (SRA) funnel, or a standard unleaded refueling nozzle, five (5) times to cycle the Capless fuel fill door. Refer to owner's manual for 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 DTCs, repeat self test, and return vehicle to customer.

- Test Failed - Go to STEP 5.

5. Connect the Mazda EVAP Emissions Tester 134-010-494 or equivalent to the vehicle and run the leak detection smoke test. Refer to MS3 online service information or Workshop Manual section 01-01 - EVAPORATIVE EMISSION SYSTEM LEAK TEST - PHASE 2 - SYSTEM LEAK CHECK and machine manufacturer's instructions.

6. Inspect the following EVAP system components while pulsing the smoke machine at 15 second intervals.

^ Hoses and connections

^ EVAP canister

^ EVAP canister vent solenoid

^ Fuel vapor tube assembly including fuel tank pressure sensor

^ Fuel tank

^ Fuel tank gasket

^ Fuel filler pipe

^ Capless fuel fill door

- No leak found - Go to STEP 8.

- Leak found - Go to STEP 7.

7. Repair vehicle per Workshop Manual instructions. Run IDS EVAP leak test again.

- Test Passed - Clear DTCs, repeat self test, and return vehicle to customer.

- Test Failed - Go to STEP 8.

NOTE:
To speed the entry of the smoke into the evaporative system and back to the Capless filler neck area, insert the Supplemental Refueling Adapter (SRA) funnel into the Capless fuel fill door.

8. Introduce smoke into the system and watch for smoke to exit through the Supplemental Refueling Adapter (SRA) funnel. When smoke appears, remove the Supplemental Refueling Adapter (SRA) funnel and close the Capless fuel filler door. Blow low pressure shop air around the Capless fuel fill door area to remove excess smoke. Watch for smoke to reappear around and/or through the fuel filler pipe refuel opening.

- No leak found - STOP - Proceed with normal Workshop Manual EVAP diagnostics.

- Leak found - Go to STEP 9.

9. Replace fuel filler pipe. Refer to MS3 online service information or Workshop Manual section 01-14 - FUEL TANK FILLER PIPE REMOVAL/INSTALLATION or FUEL TANK FILLER PIPE REMOVAL/INSTALLATION - HYBRID. Run IDS EVAP leak test again.

- Test Passed - Clear DTCs, repeat self test, and return vehicle to customer.

- Test Failed - Proceed with normal Workshop Manual EVAP diagnostics.





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