I originally only reset the battery when only the fuel cap light came on as the cap was properly secured and I hoped it was a 'glitch.'
Anyways, the tech I took it to referred me to take it to the dealer as he could only read the codes and didn't have the oem tools to actually control the computer and test the components to help find where the leak is. Simplified version of our conversation. The codes that were coming up with PO455 and PO457.
P0455 reads that there is either a fuel vapor leak or lack of purge flow in the EVAP control system.
P0457 is the check fuel cap code.
He couldn't duplicate the starting issue I had yesterday and he didn't think it was related to the EVAP problem, other than maybe the mixture was running rich which would cause some 'chugging' that my wife briefly experienced or so she says.
P0455=EVAP control system leak, either no purge flow, or large leak detected. by large leak, they usually mean a leak larger than .080.
P0457=EVAP control system leak detected(fuel filler cap loose or off.)
if you have the car back in your posesion, go out, and remove the gas cap. look very carefully at it. there is a rubber seal on it. check that, to be sure that it doesn't look cracked, or dry-rotted. if it looks ok, then look at the threading...again, very carefully. if they look ok, then look at the threading in the filler neck. the problem i mentioned before on the contours, was in the filler neck. ford(in all of their infinite wisdom) had put a plastic "lining" on the top 3 or 4 inches of the filler neck. right where the cap threads in.
if all looks ok with the cap(i kinda doubt it will), then the purge valve is somewhat common on fords too.
with fords, you need to look very carefully at pretty much everything, as one code can cause many others. this is because the system works so well, that the computer will trip a code in any system it sees a problem with....even if it's caused by another system. it makes diagnosis harder for those that don't know how to do it without datastream.
with the way you originally described the problem, i am forced to head right back to that gas cap.
something else you might want to consider.......if your mileage is low enough, you MIGHT still get this under warranty. most manufacturers cover emission control problems for 5 years or 50-60k miles i think.
if you prefer to avoid the dealer, then click this link
http://www.napaautocare.com/on the left side, type in your city, state and zip code.......it'll give you a list of the napa autocare centers near you. 99% of them will have the proper equipment to diagnose this for you.
i really cannot believe the shop you took it to turned you away. these problems are very easy to diagnose.....i use nothing more than a smoke machine for the majority of EVAP problems. if that doesn't find them, then i have a powered test light(for testing the solenoids and valves) and a DVOM for reading everythign.
i hope this has helped you at least a little bit.
let me know if i can help more, ok?
john
