fuel FORD MUSTANG 2003 Workshop Manual

z
Disconnect the fuel supply- return and vapor tube
assembly from the EVAP canister purge outlet
tube, and plug the EVAP canister purge outlet
tube.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? Yes
GO to
E6 .
No
INSTALL a new fuel supply- return
and vapor tube assembly. CARRY
OUT a leak test. REFER to
Evaporative Emission System Leak Test on this section. If the system
passes the leak test, CARRY OUT
the evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section. E6 TEST FOR EVAPORATIVE EMISSIONS TEST
PORT LEAK z
Disconnect the evaporative emissions test port
tube from the EVAP canister purge outlet tube and
plug the evaporative emissions test port tube.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? Yes
INSTALL a new evaporative
emissions test port. REFER to
Evaporative Emission Test Port
.
CARRY OUT a leak test. REFER to
Evaporative Emission System Leak Test on this section. If the system
passes the leak test, CARRY OUT
the evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
RECONNECT the evaporative
emissions test port tube to the EVAP
canister purge outlet tube. GO to E7 .
E7 TEST FOR EVAP CANISTER PURGE OUTLET
TUBE LEAK z
Disconnect the EVAP canister purge outlet tube
from the evaporative emissions canister purge
valve and plug the EVAP canister purge outlet
tube.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? Yes
INSTALL a new EVAP canister purge
outlet tube. CARRY OUT a leak test.
REFER to
Evaporative Emission System Leak Test on this section. If
the system passes the leak test,
CARRY OUT the evaporative
emission repair verification drive
cycle. REFER to Evaporative Emission Repair Verification Drive
Cycle in this section.
No
RECONNECT the EVAP canister
purge outlet tube. GO to E8 .
E8 TEST FOR LEAK AT EVAPORATIVE EMISSIONS
PURGE VALVE z
Disconnect the evaporative emissions return tube
from the evaporative emissions canister purge Yes
INSTALL a new evaporative Klj . 17 ba
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valve and plug the evaporative emissions canister
purge valve.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? emissions canister purge valve.
REFER to
Evaporative Emission Canister Purge Valve in this section.
CARRY OUT a leak test. REFER to
Evaporative Emission System Leak Test on this section. If the system
passes the leak test, CARRY OUT
the evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
INSTALL a new evaporative
emissions return tube. CARRY OUT
a leak test. REFER to Evaporative Emission System Leak Test on this
section. If the system passes the
leak test, CARRY OUT the
evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section. E9 TEST FOR BLOCKAGE IN VENTING PORTION OF
EVAP SYSTEM z
Reconnect all components.
z Connect the Evaporative Emission System Leak
Tester to the fuel filler pipe.
z Close the canister vent solenoid. Refer to Canister Vent Solenoid Closing Procedure in this section.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Open the canister vent solenoid.
z Does the pressure drop immediately? Yes
GO to
E14 .
No
GO to E10 .
E10 TEST FOR BLOCKAGE IN THE FRESH AIR VENT
HOSE z
Disconnect the fresh air vent hose from the fuel
filler pipe inside the luggage compartment.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? Yes
INSTALL a new fresh air vent hose.
CARRY OUT a leak test. REFER to
Evaporative Emission System Leak
Test in this section. If the system
passes the leak test, CARRY OUT
the evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
GO to E11 .
E11 TEST FOR BLOCKAGE IN THE FRESH AIR
TUBE ON THE FUEL FILLER PIPE ASSEMBLY z
Disconnect the fresh air tube from the fuel filler
pipe assembly. Yes
INSTALL a new fuel filler pipe Klj . 18 ba
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z
Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? assembly. REFER to
Section 310 -
01 . CARRY OUT a leak test.
REFER to Evaporative Emission System Leak Test in this section. If
the system passes the leak test,
CARRY OUT the evaporative
emission repair verification drive
cycle. REFER to Evaporative Emission Repair Verification Drive
Cycle in this section.
No
GO to E12 .
E12 TEST FOR BLOCKAGE IN THE FUEL VAPOR
CONTROL VALVE TUBE ASSEMBLY— FRESH AIR
TUBE z
Disconnect the fuel vapor control valve tube
assembly—fresh air tube from the canister vent
solenoid vent hose.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? Yes
INSTALL a new fuel vapor control
valve tube assembly—
fresh air tube.
CARRY OUT a leak test. REFER to
Evaporative Emission System Leak Test in this section. If the system
passes the leak test, CARRY OUT
the evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
GO to E13 .
E13 TEST FOR BLOCKAGE IN CANISTER VENT
SOLENOID HOSE z
Disconnect the canister vent solenoid hose from
the canister vent solenoid.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? Yes
INSTALL a new canister vent
solenoid hose. CARRY OUT a leak
test. REFER to
Evaporative Emission System Leak Test in this section. If
the system passes the leak test,
CARRY OUT the evaporative
emission repair verification drive
cycle. REFER to Evaporative Emission Repair Verification Drive
Cycle in this section.
No
INSTALL a new canister vent
solenoid. REFER to Evaporative Emission Canister Vent Solenoid in
this section. CARRY OUT a leak test.
REFER to Evaporative Emission System Leak Test in this section. If
the system passes the leak test,
CARRY OUT the evaporative
emission repair verification drive
cycle. REFER to Evaporative Klj . 19 ba
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Emission Repair Verification Drive
Cycle in this section.
E14 TEST FOR LEAK IN EVAPORATIVE EMISSIONS
CANISTER z
Carry out the Evaporative Emission Canister and
Bracket Assembly Leak Test. Refer to Evaporative Emission System Leak Test in this section.
z Does the EVAP system pass the leak test? Yes
EVAP system diagnosis complete.
GO to
E18 .
No
GO to E15 .
E15 TEST FOR CANISTER VENT SOLENOID LEAK
z
Disconnect the canister vent solenoid from the
evaporative emissions canister and plug the
canister.
z Carry out the evaporative emission system leak
test. Refer to Evaporative Emission System Leak Test in this section.
z Does the EVAP system pass the leak test? Yes
INSTALL a new canister vent
solenoid. REFER to
Evaporative Emission Canister Vent Solenoid in
this section. CARRY OUT a leak test.
REFER to Evaporative Emission System Leak Test in this section. If
the system passes the leak test,
CARRY OUT the evaporative
emission repair verification drive
cycle. REFER to Evaporative Emission Repair Verification Drive
Cycle in this section.
No
GO to E16 .
E16 TEST FOR CANISTER LEAK
z
Disconnect the EVAP canister inlet elbow from the
evaporative emissions canister and plug the EVAP
canister inlet elbow.
z Carry out the evaporative emission system leak
test. Refer to Evaporative Emission System Leak Test in this section.
z Does the EVAP system pass the leak test? Yes
INSTALL a new EVAP canister
assembly. REFER to
Evaporative Emission Canister in this section.
CARRY OUT a leak test. REFER to
Evaporative Emission System Leak Test in this section. If the system
passes the leak test, CARRY OUT
the evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
GO to E17 .
E17 TEST FOR CANISTER INLET ELBOW LEAK
z
Disconnect the fuel vapor control valve tube
assembly from the EVAP canister inlet elbow and
plug the fuel vapor control valve tube assembly. Yes
INSTALL a new evaporative
emissions canister inlet elbow.
CARRY OUT a leak test. REFER to
Evaporative Emission System Leak
Test in this section. If the system
passes the leak test, CARRY OUT
the evaporative emission repair Klj . 20 ba
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PINPOINT TEST F: UNABLE TO REFUEL VEHICLE (ORVR) z
Carry out the evaporative emissions system leak
test. Refer to Evaporative Emission System Leak Test in this section.
z Does the EVAP system pass the leak test? verification drive cycle. REFER to
Evaporative Emission Repair
Verification Drive Cycle in this
section.
No
INSTALL a new fuel vapor control
valve tube assembly. REFER to Fuel Vapor Control Tube Assembly Valve
in this section. CARRY OUT a leak
test. REFER to
Evaporative Emission System Leak Test in this section. If
the system passes the leak test,
CARRY OUT the evaporative
emission repair verification drive
cycle. REFER to Evaporative Emission Repair Verification Drive
Cycle in this section.
E18 TEST FOR LEAKAGE IN FUEL FILLER PIPE
GROMMET z
Reconnect all components.
z Connect the Evaporative Emission System Leak
Tester to the fuel filler pipe.
z Close the canister vent solenoid. Refer to Canister Vent Solenoid Closing Procedure in this section.
z Pressurize the system.
z Does the pressure drop? Yes
INSPECT fuel filler pipe to tank
grommet for cuts, abrasions or leaks.
REFER to
Section 310 - 00 for repair
procedures.
No
CARRY OUT a leak test. REFER to
Evaporative Emission System Leak Test in this section. If the system
passes the leak test, CARRY OUT
the evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section. Test Step Result / Action to Take
F1 TEST THE FUEL FILLER PIPE AND THE FUEL
FILLER PIPE CHECK VALVE z
Remove the fuel filler cap.
z Connect the Evaporative Emission System Leak
Tester to the fuel filler pipe.
z Close the canister vent solenoid. Refer to Canister Vent Solenoid Closing Procedure in this section.
z Access PCM PID FTP V.
z Pressurize the EVAP System to 3.48 kPa (14
inches H
2 O).
z Is PID FTP V reading 3.11 kPa to 3.86 kPa (12.5
to 15.5 inches H
2 O) (4.22 to 4.90 volts)? Yes
GO to
F2 .
No
GO to F10 .
F2 TEST THE EVAP SYSTEM FOR RESTRICTION
z
Connect the Evaporative Emission System Leak Yes Klj . 21 ba
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Tester to the fuel filler pipe.
z Attempt to pressurize the EVAP System to 3.48 kPa
(14 inches H
2 O).
z Does the system pressurize? GO to
F3 .
No
CARRY OUT the evaporative
emissions system leak test. REFER
to Evaporative Emission System Leak Test in this section. If the
system passes the leak test,
CARRY OUT the evaporative
emissions repair verification drive
cycle. REFER to Evaporative Emission Repair Verification Drive
Cycle in this section.
F3 TEST FOR BLOCKAGE IN FRESH AIR VENT HOSE
z
Disconnect the fresh air vent hose from the fuel filler
pipe inside the luggage compartment.
z Pressurize the EVAP system to 3.48 kPa (14 inches
H
2 O).
z Does the pressure drop immediately? Yes
INSTALL a new fresh air vent hose.
CARRY OUT a leak test. REFER to
Evaporative Emission System Leak
Test in this section. If the system
passes the leak test, CARRY OUT
the evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
GO to F4 .
F4 TEST FOR BLOCKAGE IN THE FRESH AIR TUBE
ON THE FUEL FILLER PIPE ASSEMBLY z
Disconnect the fresh air tube from the fuel filler pipe
assembly.
z Pressurize the EVAP system to 3.48 kPa (14 inches
H
2 O).
z Does the pressure drop immediately? Yes
INSTALL a new fuel filler pipe
assembly. REFER to
Section 310 -
01 . CARRY OUT a leak test.
REFER to Evaporative Emission System Leak Test in this section. If
the system passes the leak test,
CARRY OUT the evaporative
emission repair verification drive
cycle. REFER to Evaporative Emission Repair Verification Drive
Cycle in this section.
No
GO to F5 .
F5 TEST FOR BLOCKAGE IN THE TANK VAPOR
VALVE ASSEMBLY— FRESH AIR TUBE z
Disconnect the tank vapor valve assembly— fresh
air tube from the canister vent solenoid vent hose. Yes
INSTALL a new tank vapor valve
assembly—
fresh air tube. CARRY
OUT a leak test. REFER to
Evaporative Emission System Leak Test in this section. If the system
passes the leak test, CARRY OUT Klj . 22 ba
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z
Pressurize the EVAP system to 3.48 kPa (14 inches
H
2 O).
z Does the pressure drop immediately? Evaporative Emission Canister in
this section. CARRY OUT a leak
test. REFER to Evaporative Emission System Leak Test in this
section. If the system passes the
leak test, CARRY OUT the
evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
GO to F9 .
F9 TEST FOR BLOCKAGE IN CANISTER INLET
ELBOW z
Disconnect the fuel vapor control valve tube
assembly from the evaporative emissions canister
inlet elbow.
z Pressurize the EVAP system to 3.48 kPa (14 inches
H
2 O).
z Does the pressure drop immediately? Yes
INSTALL a new evaporative
emissions canister inlet elbow.
CARRY OUT a leak test. REFER to
Evaporative Emission System Leak
Test in this section. If the system
passes the leak test, CARRY OUT
the evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
GO to F10 .
F10 TEST FOR PINCHED FUEL VAPOR CONTROL
VALVE TUBE z
Lower the fuel tank 19.05 mm (3/4 inch).
z Connect the Evaporative Emission System Leak
Tester to the fuel filler pipe.
z Close the canister vent solenoid. Refer to Canister Vent Solenoid Closing Procedure in this section.
z Pressurize the EVAP system to 3.48 kPa (14 inches
H
2 O).
z Is the FTP (FTP V) PID reading 3.11 kPa to 3.86
kPa (12.5 to 15.5 inches H
2 O) (4.22 to 4.90
volts)? Yes
INSTALL a new fuel vapor control
valve tube assembly. REFER to
Fuel Vapor Control Tube Assembly
Valve in this section. CARRY OUT a
leak test. REFER to Evaporative Emission System Leak Test in this
section. If the system passes the
leak test, CARRY OUT the
evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
GO to F11 .
F11 TEST FOR BLOCKAGE IN FUEL FILLER TUBE
ASSEMBLY z
Disconnect the tank vapor recirculation tube from
the fuel filler pipe and plug both openings. Yes
INSTALL a new fuel vapor control
valve tube assembly. REFER to Klj . 24 ba
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z
Pressurize the EVAP system to 3.48 kPa (14 inches
H
2 O).
z Remove the plug from the vapor recirculation tube.
z Does the pressure drop immediately? Fuel Vapor Control Tube Assembly
Valve in this section. CARRY OUT a
leak test. REFER to Evaporative Emission System Leak Test in this
section. If the system passes the
leak test, CARRY OUT the
evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
INSTALL a new fuel filler pipe
assembly. REFER to Section 310 -
01 . CARRY OUT a leak test.
REFER to Evaporative Emission System Leak Test in this section. If
the system passes the leak test,
CARRY OUT the evaporative
emission repair verification drive
cycle. REFER to Evaporative Emission Repair Verification Drive
Cycle in this section. Klj . 25 ba
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GENERAL PROCEDURES
Canister Vent Solenoid Closing Procedure
CAUTION: The canister vent solenoid must not be energized for more than nine minutes
at one time. Once the canister vent solenoid is energized and de- energized, adequate time must
be allowed for the component to cool adequately. Failure to allow the component to cool may
create a false failure in the diagnostics, causing unnecessary repairs.
1. Connect the scan tool and select the output test mode.
2. If PID monitors are not active, select PIDs.
3. Select the fuel tank pressure (FTP) and the volts (V) parameter identification (PID) for monitoring.
4. Select the ALL OFF mode.
5. Close the canister vent solenoid by pushing the START button on the scan tool.
SECTION 303-
13: Evaporative Emissions 2003 Mustang Workshop Manual Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent scan
tool Klj . 1 ba
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GENERAL PROCEDURES
Evaporative Emission Repair Verification Drive Cycle
Drive Cycle Recommendations
NOTE:
The following procedure is designed to execute and complete the evaporative emission repair
verification drive cycle and to clear the Ford P1000, inspection and maintenance (I/M) readiness code.
When the ambient air temperature is below 4.4°C (40°F) or above 37.8°C (100°F), or the altitude is
above 2,438 meters (8,000 feet), the EVAP monitor will not run. If the P1000 must be cleared in these
conditions, the powertrain control module (PCM) must detect them once (twice on some applications)
before the EVAP monitor can be bypassed and the P1000 cleared. The EVAP bypassing procedure is
described in the following drive cycle.
1. Most OBD II monitors will complete more readily using a steady foot driving style during cruise or acceleration modes. Operating the throttle in a smooth fashion will minimize the time
necessary for monitor completion.
2. Fuel tank level should be between one- half and three-quarters full with three- quarters full being
the most desirable.
3. The evaporative monitor can only operate during the first 30 minutes of engine operation. When executing the procedure for this monitor, stay in part throttle mode and drive in a smooth
fashion to minimize fuel slosh.
Drive Cycle Preparation
NOTE: For best results, follow each of the following steps as accurately as possible.
4. NOTE: This step bypasses the engine soak timer and resets OBD II monitor status.
Install the scan tool. Turn the key ON with the engine OFF. Cycle the key off, then on. Select
the appropriate vehicle and engine qualifier. Clear all diagnostic trouble codes (DTCs) and carry
out a PCM reset.
5. Begin to monitor the following PIDs: ECT, EVAPDC, FLI (if available) and TP MODE. Press Diagnostic Data Link, PCM, PID/Data monitor and record, press trigger to select each PID, then
start.
6. Start the engine without returning the key to the OFF position.
Preparation for Monitor Entry
WARNING: Strict observance of posted speed limits and attention to driving conditions
SECTION 303-
13: Evaporative Emissions 2003 Mustang Workshop Manual Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent scan
tool Klj . 1 ba
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