Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSFORD2003WINDSTAR BASEREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCESYSTEMENGINE CONTROLS - SELF-DIAGNOSTICS INTRODUCTION - CNG, FLEX-FUEL & GASOLINESYSTEM TESTS (EVAPORATIVE EMISSION)TEST A: DTC P0442, P0456 OR P0457: SMALL LEAK DETECTED IN EVAP SYSTEMRANGER

2003 Ford Windstar Base

Test A: DTC P0442, P0456 Or P0457: Small Leak Detected In EVAP System: Ranger

2003 Ford Windstar BaseSECTION Ranger

1) Visually Inspect Components For Small Leaks

Check for presence of fuel filler cap, but DO NOT tighten or check for proper installation at this time. Ensure canister vent solenoid is fully seated on EVAP canister. Check EVAP hoses between EVAP canister and EVAP canister purge valve and EVAP canister and fuel vapor vent valve for cuts or loose connections. Check fuel filler pipe for damage. If no concerns were found, go to next step. If concern was found, repair or replace component as necessary and go to next step.

2) Check EVAP Test Port For Small System Leaks

Disconnect and plug EVAP emission return tube at intake manifold. Perform EVAPORATIVE EMISSIONS SYSTEM LEAK TEST . If EVAP system does not pass leak test, go to step 4). If system passes leak test, go to next step.

3) Visually Inspect Fuel Filler Cap

Visually inspect fuel filler cap for damage. If fuel filler cap is okay, go to next step. If fuel filler cap is damaged, replace fuel filler cap and go to next step.

4) Check For Small Leaks At Fuel Filler Cap & EVAP Test Port

Connect Evaporative Emissions System Leak Tester (134-00056) to fuel filler pipe. Close canister vent solenoid. See CANISTER VENT SOLENOID CLOSING PROCEDURE . Pressurize EVAP system to 14 in. H2O (3.48 kPa). While system is under pressure, use ultrasonic leak detector to check fuel filler cap and EVAP test port for leaks. If a leak is detected, repair or replace components as necessary and go to next step. If no leak is detected, reinstall fuel filler cap and perform EVAPORATIVE EMISSIONS SYSTEM LEAK TEST . When system passes, perform EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE .

5) Check For Concern Other Than Fuel Filler Cap

Refer to previous test results. If EVAP system did not pass EVAPORATIVE EMISSIONS SYSTEM LEAK TEST performed in step 2), go to next step. If EVAP system passed EVAPORATIVE EMISSIONS SYSTEM LEAK TEST performed in step 2), repeat EVAPORATIVE EMISSIONS SYSTEM LEAK TEST . If system now passes leak test, perform EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE .

6) Check For Small Leak With Tester Set At Fill Position

Connect evaporative emissions system leak tester to EVAP test port. Close canister vent solenoid. See CANISTER VENT SOLENOID CLOSING PROCEDURE . Set selector on evaporative emissions system leak tester to FILL position. Pressurize EVAP system to 14 in. H2O (3.48 kPa). If EVAP system pressure is 13.80-14.20 in. H2O (3.43-3.53 kPa), go to next step. If system does not hold pressure within specification, release pressure in EVAP system and go to step 8).

7) Check For Leaks In Complete EVAP System

Ensure evaporative emissions system leak tester is connected to EVAP test port. Close canister vent solenoid. See CANISTER VENT SOLENOID CLOSING PROCEDURE . Pressurize EVAP system to 14 in. H2O (3.48 kPa). While system is under pressure, use ultrasonic leak detector to 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 Canister (Canister Vent Solenoid Assembly) To Fuel Tank
- Fuel Filler Cap & Fuel Filler Tube
- EVAP Vapor Line Connections At Fuel Tank
If no leak is detected at any location, release pressure from EVAP system and go to next step. If leak is detected at any location, repair or replace component as necessary. Perform EVAPORATIVE EMISSIONS SYSTEM LEAK TEST . When system passes, perform EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE .

8) Check For Small Leak Between EVAP Return Tube To EVAP Canister

Disconnect fuel tank vapor tube at fuel tank locations and plug openings in tubes. Connect evaporative emission system leak tester to EVAP test port. Close canister vent solenoid. See CANISTER VENT SOLENOID CLOSING PROCEDURE . Pressurize EVAP system to 14 in. H2O (3.48 kPa). While system is under pressure, use ultrasonic leak detector to check EVAP system from intake manifold to EVAP canister vent solenoid. If no leak is detected, open canister vent solenoid and go to next step. If leak is detected, repair or replace component as necessary. Repeat step 6) to verify repair and go to next step.

9) Check For Small Leak Between EVAP Canister & Fuel Filler Pipe

Connect evaporative emission system leak tester to fuel filler pipe. Plug fuel vapor vent valve ports on fuel tank. Set selector on evaporative emissions system leak tester to FILL position. Pressurize EVAP system to 14 in. H2O (3.48 kPa). While system is under pressure, use ultrasonic leak detector to check fuel tank vapor tube to fuel tank for leaks. Check fuel tank pressure sensor, fuel tank vapor tube, fuel tank module and connections, fuel tank welded joints and fuel filler pipe. If no leak is detected, perform EVAPORATIVE EMISSIONS SYSTEM LEAK TEST . If EVAP system passes leak test, perform EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE . If any leak is detected, repair or replace component as necessary.

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.