2003 FORD MUSTANG Workshop Manual

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Page 2161 of 4378

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 Repair
Verification Drive Cycle in this
section.
No
GO to D9 .
D9 T

Page 2162 of 4378

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? this section. CARRY OUT a leak test.
REFER
Evaporative Emission System Leak Test in this sec

z
Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? this section. CARRY OUT a leak test.
REFER
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 D12 .
D12 TEST FOR BLOCKAGE IN EVAPORATIVE
EMISSIONS CANISTER z
Disconnect the evaporative emissions canister
inlet elbow from the evaporative emissions
canister.
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. 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 D13 .
D13 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
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 Klj . 15 ba
252003 Mustang Workshop Manual
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Page 2163 of 4378

FORD MUSTANG 2003 Workshop Manual PINPOINT TEST E: EXCESSIVE FUEL ODOR Emission Repair Verification Drive
Cycle in this section.
Test Step Result / Action to Take
E1 EVAPORATIVE EMISSION SYSTEM LEAK TEST
�z
Carry out the Evapor

PINPOINT TEST E: EXCESSIVE FUEL ODOR Emission Repair Verification Drive
Cycle in this section.
Test Step Result / Action to Take
E1 EVAPORATIVE EMISSION SYSTEM LEAK TEST
z
Carry out the Evaporative Emission System Leak
Test procedure. Refer to Evaporative Emission System Leak Test in this section.
z Does the EVAP system pass the leak test? Yes
GO to
E2 .
No
GO to E3 .
E2 CARRY OUT THE EVAPORATIVE EMISSION
SYSTEM RUNNING LOSS MONITOR REPAIR
VERIFICATION DRIVE CYCLE z
Carry out the Evaporative Emission Running Loss
Monitor Repair Verification Drive Cycle; refer to the
Powertrain Control/Emissions Diagnosis (PC/ED)
manual.
z Are the powertrain control module DTCs
retrieved? Yes
For DTCs P0442, P0455, P1443,
and P1450 REFER to the Diagnostic
Trouble Code (DTC) Index in this
section. For all other DTCs, REFER
to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for
diagnosis of the DTCs.
No
EVAP system diagnosis complete.
REFER to Symptom Chart.
E3 ISOLATE SYSTEM LEAK FROM FRONT TO REAR
z
Disconnect EVAP canister purge outlet tube from
fuel vapor control valve tube assembly and plug
both ends.
z Connect the Evaporative Emission System Leak
Tester to the evaporative emissions test port.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? Yes
GO to
E4 .
No
GO to E9 .
E4 TEST FUEL VAPOR HOSE FROM FUEL TANK TO
TUBE ASSEMBLY FUEL SUPPLY- RETURN AND
VAPOR z
Disconnect the fuel vapor return hose from the
tube assembly fuel supply- return and vapor under
vehicle, and plug the fuel supply- return and vapor
tube assembly.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? Yes
GO to
E5 .
No
INSTALL a new fuel vapor return
hose. 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.
E5 TEST THE FUEL SUPPLY-
RETURN AND VAPOR
TUBE ASSEMBLY Klj . 16 ba
252003 Mustang Workshop Manual
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Page 2164 of 4378

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

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
252003 Mustang Workshop Manual
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Page 2165 of 4378

FORD MUSTANG 2003 Workshop Manual 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.

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
252003 Mustang Workshop Manual
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Page 2166 of 4378

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? assembly. REFER to
Section 310 -
01 . CARRY OUT a leak test.
REFER to Evaporative Emission

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
252003 Mustang Workshop Manual
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Page 2167 of 4378

FORD MUSTANG 2003 Workshop Manual 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

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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Page 2168 of 4378

FORD MUSTANG 2003 Workshop Manual 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

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
252003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

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