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Old 01-11-2017, 09:27 AM   #1
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P0420 code and new catalyst

My 2012 Focus has 79,500 miles on it, and it has a pesky P0420 code that is not going away.

I know that I have limited time as the Catalyst warranty expires in 500 miles.

I took it to the dealership and had the CEL diagnosed.
It turns out that the Evap Canister was full of fuel and the purge valve was faulty.
Because the Evap canister was full of fuel, it killed my catalyst.

The dealer replaced the Evap Canister, the Purge Valve, and the Catalyst.

40 miles later, the CEL comes back on and it is P0420 again.

Any ideas? What would cause the Evap canister to fill in the first place? It's supposed to be vapor only.
I have a few theories, but I'd like to hear yours.



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Old 01-11-2017, 08:24 PM   #2
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Quote:
Originally Posted by lumpthar View Post
My 2012 Focus has 79,500 miles on it, and it has a pesky P0420 code that is not going away.

I know that I have limited time as the Catalyst warranty expires in 500 miles.

I took it to the dealership and had the CEL diagnosed.
It turns out that the Evap Canister was full of fuel and the purge valve was faulty.
Because the Evap canister was full of fuel, it killed my catalyst.

The dealer replaced the Evap Canister, the Purge Valve, and the Catalyst.

40 miles later, the CEL comes back on and it is P0420 again.

Any ideas? What would cause the Evap canister to fill in the first place? It's supposed to be vapor only.
I have a few theories, but I'd like to hear yours.
Just to add to your theory:

Evap purge valve are known to fail in the earlier models causing fuel tank to collapse.
I would check your fuel tank for deformation. It will report erratic fuel level readings when low on gas.

EDIT:

Check this... ---->P0420 hell.

Quote:
I had a P0420 at 12000 miles on a 2014 SE. It was intermittent, coming and going over a period of days, and then it wouldn't happen for a few weeks. The first time, I took it to the dealer, but the light went off as it was waiting for the service manager to look, and he said to come back when if it reappeared. After the third series of check engine lights, I took it too the dealer again, this time with the check engine light solid and not intermittent.

It took a few parts to get it fixed (under warranty):
DV6Z*5G232*A Exhaust manifold and catalyst
CP9Z*9448*A Gasket
CV6Z*9450*B Gasket
DS7Z*9F472*A Sensor - HEGO

Here's the diagnosis:
12119 MIL ON O-P1000 C-P0420 R-P1000 CATALYTIC CONVERTOR CAME APART
INTERNALLY UHEGO SENSOR THREAD S STRIPPED VERIFIED CONCERN IDS TEST
REPLACE CATALYTIC CONVERTER UHEGO SENSOR CLEAR CODE ROAD TEST MILES OUT
12119
Did they check both o2 sensor?
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Old 01-11-2017, 08:30 PM   #3
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This is the Technical Service Bulletin about the issue...MY 2012-14




(Click to read)

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Old 01-12-2017, 06:13 AM   #4
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Well....it looks like my dealer performed the first half of the TSB without performing the second half.
My fuel tank looks exactly like the photo in the TSB.

Looks like I need a fuel tank and pump now.
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