how to diagnose an EVAP system leak on Ford Explorer Fifth Generation (2011-2019)

Ford Explorer Fifth Generation (2011-2019)

Error Codes

1-2 hours

Time

medium

Difficulty

medium

Severity

Error Code: P0440, P0442, P0455

3 min read

511 words

Problem Statement

Learn how to diagnose and fix EVAP system leaks in Ford Explorer (2011-2019). Step-by-step guide with symptoms, diagnostic steps, and repair instructions.

Error Code

P0440, P0442, P0455

Affected Component

Fuel System

Estimated Time

1-2 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Disconnect battery before working on electrical systems
•Avoid smoking or open flames when working on fuel systems

Symptoms

•Check engine light illuminated
•Fuel smell near the vehicle
•Poor fuel economy
•Difficulty filling the gas tank (fuel pump keeps shutting off)
•Increased emissions

Diagnostic Steps

1
Scan for error codes using OBD-II scanner
2
Inspect all EVAP components including hoses, connections, and the gas cap for cracks, loose fittings, or damage
3
Use a smoke machine or a hand-held vacuum pump to test for leaks in the EVAP system
4
Ensure the gas cap is sealing properly; perform a pressure test if necessary
5
Check the operation of the purge valve by applying voltage to it and ensuring it opens and closes correctly
6
Inspect the charcoal canister for cracks or damage and check that it is not saturated with fuel

Solution

💡 Expert Tip

For complex repairs like this, consider taking photos at each step. This helps if you need to reverse a step or consult with a mechanic. Also, keep all removed parts organized - you may need to reference them during reassembly.

Verification

After completing the repair, verify that the issue has been resolved:

✓Test the affected component to ensure it functions correctly
✓Check for any error codes or warning lights
✓Monitor the vehicle for a few days to ensure the issue does not recur

Prevention Tips

To prevent this issue from occurring again:

•Follow the manufacturer's recommended maintenance schedule
•Address warning signs early before they develop into major issues
•Use quality parts and fluids recommended for your vehicle
•Keep detailed records of all repairs and maintenance

Tools & Equipment Required

•OBD-II scanner
•Smoke machine
•Vacuum pump
•Basic hand tools
•Safety glasses
•Gloves

Parts Required

•New gas cap
•Replacement EVAP hoses
•New purge valve

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Diagnostic Steps

1
Scan for error codes using OBD-II scanner
2
Inspect all EVAP components including hoses, connections, and the gas cap for cracks, loose fittings, or damage
3
Use a smoke machine or a hand-held vacuum pump to test for leaks in the EVAP system
4
Ensure the gas cap is sealing properly; perform a pressure test if necessary
5
Check the operation of the purge valve by applying voltage to it and ensuring it opens and closes correctly
6
Inspect the charcoal canister for cracks or damage and check that it is not saturated with fuel

Solution

1. Preparation

Tools Required: OBD-II scanner, smoke machine, vacuum pump, basic hand tools, safety glasses, gloves.
Disconnect the negative battery terminal to prevent any electrical shorts.

2. Replace Damaged Components

Gas Cap
1. Remove the old gas cap and inspect the sealing surface.
2. Install a new gas cap, ensuring it clicks securely.
EVAP Hoses
1. Locate the damaged hoses identified during the visual inspection.
2. Remove the old hoses using a hose clamp tool.
3. Install new hoses, securing them with hose clamps.
Purge Valve
1. Disconnect the electrical connector from the purge valve.
2. Remove the valve from its mounting bracket.
3. Install the new purge valve in reverse order of removal and reconnect the electrical connector.

3. Test and Reset

Reconnect the negative battery terminal.
Use an OBD-II scanner to clear any existing codes.
Test drive the vehicle to ensure the check engine light remains off.