Emissions/Engine Controls - MIL ON/DTC P0456 Set
TSB 09-20-1110/19/09
MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODE (DTC) - P0456
FORD:
2008-2009 Fusion
LINCOLN:
2008-2009 MKZ
MERCURY:
2008-2009 Milan
ISSUE
Some 2008-2009 Fusion, Milan, MKZ vehicles may exhibit a malfunction indicator light (MIL) on with diagnostic trouble code (DTC) P0456 (very small evaporative emission system leak detected - very small leak 0.020 in. (0.51 mm) diameter).
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Perform the following diagnostic steps when P0456 is found in memory. This procedure requires validation of evaporative system leak size before attempts to locate and repair leak. Use of the new Integrated Diagnostic System (IDS) evaporative leak test is required for this procedure.
NOTE
THE UPDATED IDS EVAPORATIVE LEAK TEST IS ONLY AVAILABLE ON IDS VERSION 63.04 AND HIGHER. THIS NEW CALIBRATION IS NOT INCLUDED IN THE VCM 2009.9 DVD. IF THE TEST IS NOT AN AVAILABLE SELECTION, UPDATE IDS TO THE LATEST SOFTWARE LEVEL.
NOTE
DO NOT DISTURB THE FUEL CAP UNTIL THE IDS LEAK VERIFICATION TEST IS COMPLETE.
1. Using IDS Version 63.04 and higher, access the IDS evaporative leak test.
NOTE
WHEN PERFORMING THE IDS LEAK TEST, THE FUEL LEVEL IN THE TANK MUST BE 15%-85% AS MEASURED BY FLI PID ON IDS.
2. Begin the IDS evaporative leak test. Follow the IDS screen prompts, ensuring all necessary parameters have been met, and continue test until results have been provided.
3. If test fails:
a. Check for loose or damaged fuel filler cap, clean fuel cap with a shop towel if dirty. Check fuel cap tether to ensure it is not binding and repeat IDS leak test.
(1) If test passes, clear the DTC's, repeat self test, return vehicle to customer.
(2) If test fails proceed to Step (b).
b. Connect Rotunda Vacutec(R) Smoke Machine Fuel Evaporative Emission System Tester with Built-in Nitrogen Generator (218-00015) or equivalent to the vehicle, and run the leak detection smoke test. Refer to the Powertrain Control/Emission Diagnostics (PC/ED) Pinpoint Test HX, Workshop Manual (WSM), Section 303-13, and machine manufacturer's instructions.
(1) If a leak is identified, check the evaporative hoses and connections, evaporative canister, evaporative canister vent solenoid, fuel vapor tube assembly including fuel tank pressure sensor, fuel tank, fuel tank gasket and filler pipe, repair the leak, clear the DTC's, repeat self test, and return vehicle to customer.
(2) If a leak continues to show after performing Step (b) proceed to Step 4.
NOTE
IF THE LEAK IS IN THE FILLER NECK NEAR THE FUEL TANK FILLER PIPE BRACKET, SMOKE UNDER PRESSURE MAY NOT REACH THIS LEAK. REMOVAL OF FUEL CAP TO ALLOW SMOKE TO ENTER FILLER PIPE IS NECESSARY. REFER TO POWERTRAIN CONTROLS/EMISSIONS DIAGNOSIS (PC/ED), STEP HX47 FOR ADDITIONAL INFORMATION. USE OF HIGH INTENSITY LIGHTING (Q-BEAM) IS ALSO A RECOMMENDED DIAGNOSTIC TOOL FOR DETERMINING EVAPORATIVE SYSTEM LEAKS. A HYDROCARBON (COMBUSTIBLE GAS) 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).
4. If root cause of evaporative emission system leak is unconfirmed following diagnostic routines detailed in this procedure.
a. Replace the canister vent valve (CVV) solenoid with current service level part.
b. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 63.04 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MT092011 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor
Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
9F945 42
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