fuel pressure FORD MUSTANG 2003 Manual Online

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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REMOVAL AND INSTALLATION
Fuel Vapor Vent Valve
Removal and Installation
1. NOTE: The fuel vapor vent valve is repaired along with the fuel vapor control valve and the in-
line fuel tank pressure sensor as a fuel vapor control valve tube assembly.
For removal and installation of the fuel vapor vent valve, refer to Fuel Vapor Control Tube Assembly Valve in this section.
SECTION 303-
13: Evaporative Emissions 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Fuel Vapor Control Tube Assembly Valve
Removal and Installation
1. Remove the fuel tank. For additional information, refer to Section 310 - 01 .
2. Remove the retainers.
3. NOTE: The fuel vapor vent valve, fuel vapor control valve and the in- line fuel tank pressure
sensor are repaired as a fuel vapor control valve tube assembly.
NOTE: It may be necessary to lubricate the fuel vapor control valve tube assembly grommets
with ESE- M00B144- B Merpol® or equivalent to assist in the removal procedure.
Remove the fuel vapor control valve tube assembly. 1. Loosen the fuel vapor vent valve.
2. Loosen the fuel vapor control valve.
3. Remove the fuel vapor control valve tube assembly.
4. NOTE: Lubricate all O- ring seals with MERPOL® O-Ring Seal Lubricant or equivalent meeting
Ford specification ESE-M99B144- B.
NOTE: New grommets are necessary when the fuel vapor control valve tube assembly is
removed.
To install, reverse the removal procedure.
zLeak test the system. For additional information, refer to Evaporative Emission System Leak Test in this section.
z Carry out the evaporative emission repair verification drive cycle. For additional
SECTION 303-
13: Evaporative Emissions 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Fuel Tank Pressure Sensor
Removal and Installation
1. NOTE: The in-line fuel tank pressure sensor is repaired along with the fuel vapor vent valve and
the fuel vapor control valve as a fuel vapor control valve tube assembly.
For removal and installation of the fuel vapor control valve, refer to Fuel Vapor Control Tube Assembly Valve in this section.
SECTION 303-
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SPECIFICATIONS
SECTION 303-
14: Electronic Engine Controls 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants
Super premium SAE 5W-
20 Engine Oil XO-5W20-DSP WSS-
M2C914- A Penetrating and Lock Lubricant E8AZ-19A501-
B N/A
Pipe Sealant with Teflon D8AZ-19554-
A WSK-
M26350- A2
Torque Specifications Description Nm lb-
ft lb-
in Cylinder head temperature (CHT) sensor —
3.8L 10 — 89
Engine coolant temperature (ECT) sensor —
4.6L (2V) 20 — 15
Engine coolant temperature (ECT) sensor —
4.6L (4V) 24 18 —
Heated oxygen sensors (HO2S) 41 30 —
Catalyst monitor sensors 41 30 —
Crankshaft position (CKP) sensor bolts —
3.8L 6 — 53
Crankshaft position (CKP) sensor bolts —
4.6L 10 — 89
Power steering reservoir bolts 10 — 89
Camshaft position (CMP) sensor bolt —
4.6L 10 — 89
PCM connector to module bolt 6 — 53
Idle air control (IAC) valve bolts 10 — 89
Camshaft synchronizer housing bolt 25 18 —
Throttle position (TP) sensor screws 3 — 27
Fuel pressure sensor bolts 4 — 35
Air intake scoop bolts 25 18 —
Air intake scoop bracket bolt 25 18 —
Air intake scoop bracket nuts 25 18 —
Air intake scoop bracket throttle body nut 9 — 80
Exhaust gas recirculation (EGR) vacuum regulator solenoid bolts 10 — 89 Klj . 1 ba
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REMOVAL AND INSTALLATION
Fuel Pressure Sensor
Removal
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. Failure to follow these instructions may result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before working on or disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be relieved. Failure to follow these instructions
may result in personal injury.
Mach I
1. Remove the air intake scoop. For additional information, refer to Section 303 - 12 .
All engines 2. Relieve the fuel pressure. For additional information, refer to Section 310 - 00 .
3. NOTE: The 4.6L (4V) Cobra engine is shown, the other engines are similar.
Disconnect the connector and the vacuum line. 4. Remove the bolts and the sensor. SECTION 303-
14: Electronic Engine Controls 2003 Mustang Workshop Manual Material
Item Specification
Super Premium SAE 5W-20
Motor Oil
XO- 5W20- DSP or equivalent WSS-
M2C914-
A Klj . 1 ba
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