Fulltext TSBs

Technical Service Bulletins

TSB
08-4-3
  • MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODE (DTC) – P0456
Publication Date: February 7, 2008

FORD:
2007-2008 E-150, E-250, E-350, Expedition, F-150
LINCOLN:
2007-2008 Mark LT, Navigator

This article supersedes TSB 07-16-18 to update the Service Procedure.

ISSUE:

Some 2007, 2008 Expedition, Navigator, E-150 through E-350, F-150 and Mark LT may exhibit a MIL on with DTC P0456 (very small evaporative system leak – 0.020 in diameter (0.51 mm)).

ACTION:

Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

Perform the following diagnostic steps when P0456 is found in memory. Procedure requires validation of evaporative system leak size before attempts to locate and repair leak. Use of a Vacutec leak machine or equivalent machine is required for this procedure.

NOTE:CURRENTLY IDS EVAP LEAK MEASUREMENT TOOL IS NOT CAPABLE OF MEASURING LEAKS BELOW 0.035 IN DIAMETER. IDS CANNOT BE USED TO MEASURE LEAK SIZE, OR VALIDATE REPAIR, FOR DTC P0456.

NOTE:MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR DAMAGED FUEL CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE CAP UNTIL THE LEAK VERIFICATION PRESSURE TEST (STEP 2) IS COMPLETE.

Before attempting to locate or repair leak(s), first verify leak size using Vacutec machine.

  1. Prepare the vehicle for hook up to the Rotunda Vacutec or equivalent machine.

    NOTE:REFER TO THE WORKSHOP MANUAL FOR ALL WARNINGS AND SAFETY REQUIREMENTS.

    NOTE:REFER TO THE VACUTEC MACHINE OPERATOR MANUAL FOR ADDITIONAL INSTRUCTIONS AND FOR HELPFUL TIPS.

    NOTE:WHEN USING THE VACUTEC MACHINE, THE FUEL LEVEL IN THE TANK MUST BE GREATER THAN 15% AND LESS THAN 85% (AS MEASURED BY FLI PID USING IDS).

    • Key in off position.
    • Connect the Vacutec machine power cables to the vehicle battery.
    • Check to see that the Vacutec power indicator lamp is on, indicating good battery contact.
    • Disconnect the fuel vapor to intake manifold line at the electrical vapor management valve (eVMV) and cap the line.
    • Connect a 5/16″ ID flexible vinyl clear hose with a wall thickness of 1/16″ to the eVMV. This will be used in Step 2 to connect the Vacutec. (Figure 1)



    Figure 1 – Article 08-4-3

  2. Run the Vacutec machine leak verification pressure test.
    1. Position the control lever located on the Vacutec machine to meter.
    2. Calibrate the Vacutec machine flow meter using the 0.020 (DTC P0456) standard as follows.
      1. Insert the transparent air supply hose nozzle tip into the 0.020 inch calibrated leak located on the front of the Vacutec machine.
      2. Press the remote starter button on the Vacutec machine. Observe the position of the flow meter indicator ball.
      3. Position the flow meter red pointer flag so that it aligns with the bottom of the indicator ball. (Figure 2)
      4. Release the button and remove the transparent air supply hose nozzle tip from Vacutec machine.
    3. Connect the transparent air supply hose nozzle tip into the hose adapter from Step 1. (Figure 1)
    4. Press the remote starter button on the Vacutec machine.
    5. Observe that the position of the flow meter indicator ball goes from the top of the meter to the very bottom. (Figure 2)
    6. This validates you have properly sealed connections between the Vacutec and eVMV.
    7. Key on, engine off.
    8. Using IDS, access the PCM and control the canister vent valve (CVV) ( EVAPCV PID) and the eVMV (EVMV PID).
    9. Close the CVV by commanding the EVAPCV PID to on (100% duty cycle).
    10. Open the eVMV valve by commanding the EVMV PID to on (1,000 mA).
    11. Press the remote starter button on the Vacutec machine. Notice that the ball in the flow meter is all the way at the top. This indicates the system is being pressurized.
    12. Continue to press the remote starter button until the ball stops descending and stabilizes for 30 seconds (takes between 3-5 minutes). If the ball: (Figure 2)


      Figure 2 – Article 08-4-3

      1. Is at least 1 ball size below the indicator flag, the EVAP system has PASSED the leak test.
      2. Is at or above the indicator flag, the EVAP system has FAILED the leak test.
    13. Document on the warranty claim, TSB number and test result pass or fail.
      1. If test passes, clear the DTCs, repeat self-test, and return to customer.
      2. If test fails:
        1. First, check for loose or damaged fuel filler cap, and clean with a shop rag if dirty. Check for the tether binding and re-run Vacutec leak test if adjustment/cleaning is made to fuel cap. If test passes, clear the DTCs, repeat self-test, and return to customer. If not, proceed to step (b).
        2. Then check the CVV function by capping off the fresh air hose near the CVV and re-run Vacutec leak test. If leak test now passes, replace CVV and then verify repair. If test passes, clear the DTCs, repeat self-test, and return to customer. If not, proceed to step (c).
        3. If leak is not isolated to fuel cap or vent valve with above procedure, the Vacutec smoke test in Step 3 is required to isolate the location(s) of leak.
  3. Run Vacutec machine leak detection smoke test.
    1. Position the control lever located on the Vacutec machine to smoke.
    2. Remove the fuel filler cap.
    3. Remove the Vacutec's transparent air supply hose from the hose adapter and replace it with the black smoke supply hose.
    4. Key on, engine off.
    5. As in Step 2, use IDS to access the PCM and control the canister vent valve CVV (EVAPCV PID) and the eVMV (EVMV PID).
      1. Close the CVV by commanding the EVAPCV PID to on (100% duty cycle).
    6. Open the eVMV valve by commanding the EVMV PID to on (1,000 mA).
    7. Press the remote starter button on the Vacutec machine to introduce smoke into the EVAP system. If smoke does not exit the fuel filler neck after the system is pressurized, command the EVAPCV PID open (off) to allow air to purge the CVV solenoid. Once smoke is seen at the CVV solenoid, command the EVAPCV PID closed (on).
      1. Secure the fuel filler cap once smoke is observed exiting the fuel tank neck area.
      2. Continue to introduce smoke into the system for 60 seconds to obtain pressure.
      3. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off while checking for exiting smoke.
      4. Use the halogen spotlight provided with the Vacutec machine to follow the EVAP system path and look for smoke exiting at leak points.

        NOTE:A HYDROCARBON DETECTOR CAN BE AN EFFECTIVE MEANS TO LOCATE LEAK(S) IN LOCATIONS WHERE SMOKE EXIT IS NOT VISIBLE SUCH AS TOP OF FUEL TANK (DO NOT USE REFRIGERANT LEAK DETECTOR).

    8. Proceed through the following inspection procedure while pulsing the smoke machine at 15 second intervals:
      1. Check the EVAP hoses and connections, eVMV valve, CVV solenoid, EVAP carbon canister, fuel tank, fuel tank gasket, fuel filler pipe, around the fuel tank area, and at the fuel filler cap.
      2. Wiggle the components and connections to simulate road bumps while looking for signs of leaking smoke.
      3. If the leak is not detected from the top, check the EVAP system for leaks from under the vehicle.

        NOTE:IF THE LEAK IS IN THE FUEL FILLER NECK BETWEEN THE CHECK VALVE AND THE FUEL FILLER CAP, SMOKE UNDER PRESSURE MAY NOT REACH THE LEAK. IF LEAKING SMOKE IS NOT FOUND, A THOROUGH VISUAL INSPECTION OF THE FUEL FILLER NECK AND FUEL FILLER CAP SHOULD BE DONE.

  4. Repair source of leak. Verify leak repair with Vacutec machine as in Step 2. Connect all the disconnected components and clear codes.

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

OPERATIONDESCRIPTIONTIME
080403A2007-2008 Expedition/Navigator/F-150/Mark LT/ Econoline 250/350: Perform Evaporative Emissions System Tests Described In The Service Procedure Of This Article (Do Not Use With 12650D, 9000D, 9000D1, 9000D2)0.9 Hr.
MT080403If Repairs Are Necessary Use SLTS Operations If Available Or Actual Time.Actual Time

DEALER CODING

BASIC PART NO.CONDITION CODE
DIAG42