fuel cap FORD MUSTANG 2003 Owner's Manual

3. If the concern remains after the inspection, connect the scan tool to the data link connector
(DLC) located beneath the instrument panel and select the vehicle to be tested from the scan
tool menu. If the scan tool does not communicate with the vehicle:
zcheck that the program card is correctly installed.
z check the connections to the vehicle.
z check the ignition switch position.
4. If the scan tool still does not communicate with the vehicle, refer to the scan tool manual.
5. Carry out the DATA LINK DIAGNOSTICS test. If the scan tool responds with:
z CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418 - 00 .
z NO RESP/NOT EQUIP for PCM, refer to the Powertrain Control/Emissions Diagnosis (PC/ED)
manual.
z SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase
the continuous DTCs and carry out the PCM KOEO self- test.
6. If the DTCs retrieved are related to the concern, go to the PCM Diagnostic Trouble Code (DTC) Index to continue diagnostics.
7. If the concern remains after the inspection, determine the symptom. GO to Symptom Chart .
PCM Diagnostics Trouble Code (DTC) Index
Symptom Chart z
EVAP lines or hoses
z Vacuum lines or hoses DTC Description Source Action
P0442 Small leak detected in EVAP system
(As small as 1.02 mm [0.040 inch]) PCM Go To Pinpoint Test A .
P0455 Major leak or no flow detected PCM Go To Pinpoint Test B .
P0457 Check for missing or leaking fuel filter
cap PCM Go To Pinpoint Test A .
P1443 Very small or no purge flow detected PCM Go To Pinpoint Test B .
P1450 Excessive vacuum detected in the fuel
tank PCM Go To Pinpoint Test C .
— Any other PCM DTC PCM REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED)
manual.
SYMPTOM CHART Condition
Possible Sources Action
z Hissing sound when
removing fuel cap z
Canister vent solenoid.
z Evaporative emissions
canister.
z Fuel vapor control valve z
Go To Pinpoint Test D . Klj . 4 ba
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Pinpoint Tests
NOTE:
Reinstall or install new evaporative emission hose clamps removed or damaged during testing
procedures.
PINPOINT TEST A: DTC P0442 SMALL LEAK IN EVAP SYSTEM tube assembly.
z EVAP canister tube.
z EVAP canister purge
outlet tube.
z Excessive fuel odor zCanister vent solenoid.
z Evaporative emissions
canister.
z Fuel vapor control valve
tube assembly.
z Evaporative emissions
test port.
z EVAP canister purge
outlet tube. z
Go To Pinpoint Test E .
z Unable to refuel vehicle zFuel filler pipe.
z Canister vent solenoid.
z Fuel vapor control valve
tube assembly. z
Go To Pinpoint Test D .
Test Step Result / Action to Take
NOTE:
Condition P0442 DTC set: less than 0.625 kPa (2.5 inches H
2 O) bleed-
up over 15
seconds at 75% fuel fill. Vapor generation limit: more than 0.625 kPa (2.5 inches H 2 O) over 120
seconds. A1 VISUALLY INSPECT THE
COMPONENTS FOR SMALL LEAKS z
Check for the presence of a fuel filler
cap. Do not tighten or check for correct
installation at this time.
z Verify the canister vent solenoid is
correctly seated on the EVAP canister.
z Check for cut or loose connections to
fuel vapor hoses, tubes and
connections in the following locations:
„EVAP canister to EVAP canister
purge valve
„ EVAP canister to fuel vapor vent
valve assembly
„ fuel vapor control valve tube
assembly to fuel tank
z Check the fuel filler pipe for damage.
z Is a concern with a hose, tube,
connection or valve visually
evident? Yes
REPAIR or INSTALL new components as
necessary.GO to
A2 .
No
GO to A2 .
A2 CHECK AT THE EVAP TEST PORT
FOR SMALL SYSTEM LEAKS z
Disconnect and plug the evaporative
emission return tube at the intake Yes
GO to
A3 . Klj . 5 ba
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manifold.
z Complete the evaporative emission
system leak test. Refer to Evaporative Emission System Leak Test in this
section.
z Does the system pass the leak test? No
GO to
A4 .
A3 VISUALLY INSPECT THE FUEL
FILLER CAP z
Visually inspect the fuel filler cap for
damage.
z Is the fuel filler cap damaged? Yes
INSTALL a new fuel filler cap. GO to
A4 .
No
GO to A4 .
A4 CHECK FOR SMALL LEAKS AT THE
FUEL FILLER CAP AND EVAP TEST PORT z
Connect the Evaporative Emission
System Leak Tester to the fuel filler
pipe.
z Key in ON position.
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 Using the ultrasonic leak detector,
check the fuel filler cap and EVAP test
port for leaks.
z Is a leak detected? Yes
REPAIR or INSTALL new components as
necessary. GO to
A5 .
No
INSTALL the fuel filler cap. CARRY OUT the
evaporative emission 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. A5 CHECK FOR CONCERN OTHER THAN
THE FUEL FILLER CAP z
Refer to previous test results.
z Did the system pass the evaporative
emission system leak test carried
out in pinpoint test Step A2? Yes
CARRY OUT the evaporative emission system
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 the fuel filler cap. GO to A6 .
A6 CHECK FOR SMALL LEAK WITH
TESTER SET AT FILL POSITION z
Connect the Evaporative Emission
System Leak Tester to the EVAP test
port.
z Key in ON position.
z Close the canister vent solenoid. Refer
to Canister Vent Solenoid Closing Procedure in this section.
z Turn the selector on the Evaporative
Emission System Leak Tester to the
FILL position.
z Pressurize the EVAP system to 3.48
kPa (14 inches H
2 O).
z Does the pressure on the EVAP
system hold between 3.43 kPa and
3.53 kPa (13.80 inches and 14.20 Yes
GO to
A7 .
No
DISCONTINUE pressurizing the system. GO to
A8 . Klj . 6 ba
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inches H
2 O)? A7 CHECK FOR LEAKS IN THE
COMPLETE EVAP SYSTEM z
Connect the Evaporative Emission
System Leak Tester to the EVAP test
port.
z Key in ON position.
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 Using the ultrasonic leak detector,
check the following EVAP system
locations:
„EVAP return tube to EVAP
canister purge valve
„ EVAP canister purge valve to
EVAP canister— canister vent
solenoid assembly
„ EVAP canister — canister vent
solenoid assembly to fuel tank
„ fuel filler cap and fuel filler tube
z Is a leak detected at EVAP return
tube, EVAP canister purge outlet
tube or EVAP canister tube or
associated hose? Yes
REPAIR or INSTALL new components as
necessary. CARRY OUT the evaporative
emission 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.
No
DISCONTINUE pressurizing the system. GO to
A8 .
A8 CHECK FOR SMALL LEAK FROM THE
EVAP RETURN TUBE TO THE FUEL
VAPOR TEE z
Disconnect the EVAP canister purge
outlet tube at the fuel vapor tee. Plug
the opening in the EVAP canister
purge outlet tube.
z Connect the Evaporative Emission
System Leak Tester to the EVAP test
port.
z Pressurize the EVAP system to 3.48
kPa (14 inches H
2 O).
z Using the ultrasonic leak detector,
check the EVAP system from the
intake manifold to the EVAP canister
purge outlet tube.
z Is a leak detected? Yes
REPAIR or INSTALL new components as
necessary. REPEAT Step A6 to verify the repair.
GO to
A9 .
No
GO to A9 .
A9 CHECK FOR SMALL LEAK BETWEEN
EVAP CANISTER AND FUEL TANK FILLER
PIPE z
Connect the Evaporative Emission
System Leak Tester to the fuel filler
pipe.
z Transfer the plug from the EVAP
canister purge outlet tube to the fuel
vapor tee.
z Turn the Evaporative Emission System
Leak Tester selector to the FILL
position.
z Key in ON position.
z Close the canister vent solenoid. Refer
to Canister Vent Solenoid Closing Yes
REPAIR or INSTALL new components as
necessary.
GO to
A10 .
No
GO to A10 . Klj . 7 ba
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PINPOINT TEST B: DTC P0455 MAJOR LEAK OR NO FLOW
DETECTED OR DTC P1443 VERY SMALL OR NO PURGE FLOW
DETECTED IN SYSTEM Procedure in this section.
z Pressurize the EVAP system to 3.48
kPa (14 inches H
2 O).
z Using the ultrasonic leak detector,
check the fuel vapor control valve tube
to the fuel tank for leaks. Check the
fuel tank pressure sensor, fuel vapor
control valve tube and the fuel filler
pipe. Check fuel tank to EVAP canister
-canister vent solenoid.
z Is a leak detected? A10 CHECK EVAP SYSTEM AT FUEL
FILLER PIPE z
Reconnect the EVAP canister purge
outlet tube to the fuel vapor tee.
z Complete 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
RESTORE the system to normal operation.
CARRY OUT the evaporative emission 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.
No
GO to A6 .
Test Step Result / Action to Take
NOTE:
Condition DTC P0455 set: – 1.74 kPa (-7.0 inches H
2 O) over 30 seconds. NOTE:
Condition DTC P1443 set: – 1.74 kPa (-7.0 inches H
2 O) over 30 seconds with more than
0.02 lb/min vapor flow. B1 CHECK FOR DIAGNOSTIC
TROUBLE CODE P0455 OR
P1443 z
Use the recorded results
from the PCM DTCs.
z Is DTC P0455 present? Yes
GO to
B2 .
No
GO to B3 .
B2 VISUALLY CHECK FOR
GROSS EVAP SYSTEM LEAKS z
Check for the presence of a
fuel filler cap. Do not tighten
or check for correct
installation at this time.
z Check the input port
vacuum and EVAP return
tube are connected to the
EVAP canister purge valve.
z Check that the canister vent
solenoid is correctly
attached to the EVAP Yes
REPAIR or INSTALL new EVAP components as necessary.
GO to
B3 .
No
GO to B3 . Klj . 8 ba
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canister.
z Check for disconnected or
cracked fuel vapor hoses or
tubes between the intake
manifold and following
components:
„EVAP canister purge
valve
„ EVAP canister
„ fuel vapor vent valve
assembly
„ fuel vapor control
valve tube assembly
z Check for damaged fuel
tank or fuel filler pipe.
z Is a concern with a hose,
tube, connection or valve
visually evident? B3 CHECK FOR EVAP SYSTEM
LEAKS z
Disconnect the EVAP return
tube from the intake
manifold and plug the EVAP
return tube.
z Connect the Evaporative
Emissions System Leak
Tester to the EVAP test
port.
z Carry out the evaporative
emissions system leak test.
Refer to Evaporative Emission System Leak Test
in this section.
z Does the system pressure
stay above 1.99 kPa (8
inches H
2 O)? Yes
GO to
B4 .
No
VERIFY that the fuel filler cap is installed correctly. REPAIR
or INSTALL new components as necessary. CARRY OUT
the evaporative emission system 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. B4 CHECK FOR BLOCKAGE
BETWEEN THE EVAP
CANISTER PURGE VALVE AND
FUEL VAPOR TEE z
Key in ON position.
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. Refer to Canister Vent Solenoid Closing
Procedure in this section.
z Does the pressure drop
immediately? Yes
GO to
B5 .
No
INSTALL a new vapor line between the EVAP canister
purge valve and the fuel vapor tee. CARRY OUT the
evaporative emission system 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. B5 CHECK FOR BLOCKAGE
BETWEEN FUEL FILLER PIPE
AND THE FUEL VAPOR TEE z
Connect the Evaporative
Emissions System Leak Yes
GO to
B6 . Klj . 9 ba
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PINPOINT TEST D: HISSING SOUND WHEN REMOVING FUEL CAP z
Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? GO to
Pinpoint Test D .
C3 CHECK FOR BLOCKAGE BETWEEN THE FUEL
FILLER PIPE AND THE FUEL VAPOR TEE z
Connect the Evaporative Emission System Leak
Tester to the fuel filler pipe.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? Yes
GO to
C4 .
No
GO to Pinpoint Test D .
C4 CHECK FOR FUEL TANK PRESSURE SENSOR
PID WITHOUT PRESSURE APPLIED z
Disconnect the EVAP canister outlet tube at the
EVAP canister.
z Key in ON position.
z Access PCM PID FTP V.
z Record the reading.
z Is PID FTP V reading between 2.40 and 2.80
volts? Yes
GO to
C5 .
No
REFER to Powertrain
Control/Emissions Diagnosis (PC/ED)
manual to continue diagnosis. C5 CHECK FOR STUCK OPEN EVAP CANISTER
PURGE VALVE CONDITION AT IDLE z
Connect the EVAP canister outlet tube.
z Remove the plug from the EVAP return tube and
reconnect the tube to the intake manifold.
z Verify that the fuel filler cap is correctly installed.
z Key in ON position.
z Access PCM PIDs FTP V and EVAPPDC.
z Start the engine and allow to idle.
z Monitor the FTP V and EVAPPDC PIDs.
z When PID EVAPPDC is zero, is PID FTP V
reading below 2.40 volts? Yes
INSTALL a new EVAP canister purge
valve. REFER to
Evaporative Emission Canister Purge Valve in this section.
CARRY OUT an EVAP system leak
test. REFER to Evaporative Emission System Leak Test in this section. If the
system passes the leak test, CARRY
OUT an evaporative emissions repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this section.
No
CARRY OUT the EVAP 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. Klj . 11 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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SPECIFICATIONS
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual General Specifications
Item Specification
Fuel tank capacity 59.42 liters (15.7 gallons)
Key on, engine off fuel pressure 207-
345 kPa
(30-50 psi) Engine running fuel pressure (idle) 152-
255 kPa
(27-37 psi) Lubricants
SAE 5W-
20 Super Premium Synthetic Blend Motor Oil XO-5W20- QSP WSS-
M2C153- H Klj . 1 ba
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GENERAL PROCEDURES
Pressure Relief
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, resulting in possible personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before servicing or disconnecting any of the fuel lines or fuel system components,
the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing
personal injury or a fire hazard.
1. Remove the Schrader valve cap and install the Fuel Pressure Gauge.
2. CAUTION: Open the manual valve slowly on the Fuel Pressure Gauge.
Relieve the fuel pressure. zPlace the fuel in a suitable container.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Fuel Pressure Gauge
310-
012 (T80L-9974- B) Klj . 1 ba
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