FORD MUSTANG 2003 Workshop Manual

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 System Leak Test
CAUTION: The evaporative emission system must not be pressurized to more than 3.48
kPa (14 inches H 2 O) or damage to the evaporative emission system may occur.
1. Connect the Evaporative Emission System Leak Tester to the evaporative emission test port.
2. Close the canister vent solenoid. For additional information, refer to Canister Vent Solenoid Closing Procedure in this section.
3. Pressurize the evaporative emission system to 3.48 kPa (14 inches H 2 O).
4. Monitor the system for two minutes. The system fails the leak test if the pressure falls below 2.0 kPa (8 inches H 2 O).
5. Repair any leaks as necessary.
6. Repeat the leak test until the system remains above 2.0 kPa (8 inches H 2 O) after the two-
minute test period.
SECTION 303-
13: Evaporative Emissions 2003 Mustang Workshop Manual Special Tool(s)
Evaporative Emission System
Tester 310-
F007
(134- 00056) or equivalent Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent scan
tool Klj . 1 ba
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Klj . 2 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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are mandatory when proceeding through the following drive cycle.
7. NOTE: This step allows engine warm- up and provides intake air temperature (IAT) input to the
PCM.
Idle the vehicle for 15 seconds. Drive at 64 km/h (40 mph) until the ECT is at least 76.7°C (170°
F).
8. Is IAT above 4.4°C (40°F) and below 37.8°C (100°F)? If not, continue with the following steps but note that the EVAP Monitor Bypass portion of the drive cycle (Step 13) will be required to
bypass the EVAP monitor and clear the P1000.
9. NOTE: This step executes the heated oxygen sensor (HO2S) monitor.
Cruise at 64 km/h (40 mph) for 60 seconds.
10. NOTE: This executes the EVAP monitor if IAT is above 4.4°C (40°F) and below 37.8°C (100°F).
NOTE: To initiate the monitor, TP MODE should equal PT, EVAPDC must be greater than 75%,
and FLI must be between 15 and 85%.
NOTE: Avoid sharp turns and hills.
Cruise at 72 to 104 km/h (45 to 65 mph) for 10 minutes.
11. NOTE: This step executes the ISC portion of the Secondary Air/CCM.
Bring the vehicle to a stop. Idle with the transmission in DRIVE (for automatic transmission) or
NEUTRAL (for manual transmission) for two minutes.
Pending Code and EVAP Monitor Bypass Check
12. NOTE: This determines if a pending code is preventing the clearing of P1000.
NOTE: If the EVAP monitor is not complete and IAT was below 4.4°C (40°F) or above 37.8°C
(100°F) temperature range in Step 8, or the altitude is above 2,438 meters (8,000 feet), the
EVAP Monitor Bypass (Step 13) must be carried out.
Using the scan tool, check for pending codes. Conduct normal repair procedures for any
pending code concerns. Rerun any incomplete monitor.
EVAP Monitor Bypass
13. NOTE: This allows the bypass counter to increment to two.
NOTE: Do not repeat Step 4.
Park the vehicle for a minimum of eight hours. Repeat Steps 5 through 12. Klj . 2 ba
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REMOVAL AND INSTALLATION
Evaporative Emission Canister
Removal and Installation
1. WARNING: The evaporative emission system contains fuel vapor and condensed
fuel vapor. Although not in large quantities, it still presents the danger of explosion or
fire. Disconnect the battery ground cable from the battery to minimize the possibility of
an electrical spark occurring, possibly causing a fire or explosion if fuel vapor or liquid
fuel is present in the area. Failure to follow these instructions may result in personal
injury.
Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the left rear wheel. For additional information, refer to Section 204 - 04 .
4. WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or around any fuel- related component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in personal
injury.
Disconnect the canister vent solenoid hose assembly.
5. Disconnect the connector.
6. Disconnect the evaporative emission (EVAP) canister purge outlet tube.
SECTION 303-
13: Evaporative Emissions 2003 Mustang Workshop Manual Klj . 1 ba
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7. Remove the EVAP canister with bracket assembly from the vehicle.
zRemove the bolts.
8. Disconnect the brace.
9. Remove the canister vent solenoid and canister vent solenoid hose assembly. 10. Remove the EVAP canister purge outlet tube elbow. Klj . 2 ba
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