Milan FWD L4-2.3L (2008)
Engine Control Module: All Technical Service Bulletins
Emissions/Engine Controls - MIL ON/DTC P0456 Set
TSB 09-20-11
10/19/09
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
