2003 FORD MUSTANG lock

8. Disconnect the vacuum hose.
9. Disconnect the fuel supply spring lock coupler. For additional information, refer to
Section 310 -
00 .
10. Disconnect the accelerator controls. zDisconnect the accelerator cable.
z If equipped, disconnect the speed control cable. 11. Remove the accelerator cable bracket bolts. Klj . 2 ba
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To start the testing, conditions of stable purging and vehicle speed must be satisfied. During the first
stage, the canister vent solenoid is closed, while the EVAP canister purge valve remains open,
applying and building vacuum in the system as indicated by the FTP sensor. This phase checks for
major leaks in the EVAP system.
In the second stage, the EVAP canister purge valve closes and the system looks for minimal decay
rate in the EVAP vacuum, indicating the absence of any small EVAP system leaks.
The last stage is entered only if stage two of the leak test has failed and checks whether the failed test
was due to excess vapor generation. It monitors fuel vapor generation rate. Initially, the canister vent
solenoid is opened to equalize EVAP system pressure to atmosphere. Then the canister vent solenoid
is closed, allowing pressure to build if vapor generation is present in sufficient quantity. If the rate of
generation is found to be too high, the EVAP running loss system leak test is aborted. If not, then a
small leak is diagnosed.
On-
Board Refueling Vapor Recovery (ORVR) Evaporative Emission (EVAP) System
The basic elements forming the ORVR system are as follows:
zThe fuel filler pipe forms a seal to prevent vapors from escaping the fuel tank while liquid is
entering the fuel tank. Liquid in the one inch diameter tube blocks vapors from rushing back up
the fuel filler pipe.
z A fuel vapor control valve controls the flow of vapors out of the fuel tank. The valve closes when
the liquid level reaches a height associated with fuel tank usable capacity. The valve
accomplishes the following:
„limits the total amount of fuel that can be dispensed into the fuel tank
„ prevents liquid gasoline from exiting the fuel tank when submerged (as well as when
tipped well beyond a horizontal plane as part of the vehicle rollover protection in road
accidents)
„ minimizes vapor flow resistance during anticipated refueling conditions
z Fuel vapor tubing connects the fuel vapor control valve to the EVAP canister. This routes the
fuel tank vapors, displaced by the incoming liquid, to the EVAP canister.
z A check valve in the fuel filling system prevents liquid from rushing back up the fuel filler pipe
during the liquid flow variations associated with the filler nozzle shut- off.
Between refueling events, the EVAP canister is purged with fresh air so that it may be used again to
store vapors accumulated during engine soaks or subsequent refueling events. The vapors drawn off
of the carbon in the EVAP canister are consumed by the engine.
Inspection and Verification 1. Verify the customer concern is with the evaporative emission (EVAP) system.
2. Visually inspect for the following obvious signs of mechanical damage.
Visual Inspection Chart Mechanical
z
Fuel filler cap
z EVAP test port
z EVAP canister or canister vent solenoid Klj . 3 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 C: DTC P1450 EXCESSIVE VACUUM DETECTED IN
THE FUEL TANK Tester to the fuel filler pipe.
z Pressurize the EVAP
system to 6.47 to 6.97 kPa
(26 to 28 inches H
2 O).
z Does the pressure drop
immediately? No
INSTALL new fuel tank vapor line(s). REPEAT pinpoint test
Step B5 to verify the repair. 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.
B6 CHECK FOR FAILED EVAP
CANISTER PURGE VALVE OR
FUEL TANK PRESSURE
SENSOR z
Use the recorded results
from the PCM DTCs.
z Are DTC codes P0455 and
P1443 present? Yes
INSTALL a new EVAP canister purge valve. REFER to
Evaporative Emission Canister Purge Valve
in this section.
CARRY OUT the evaporative emission system leak test.
REFER to Evaporative Emission System Leak Test in this
section. If no leak is detected, CARRY OUT the evaporative
emissions repair verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
INSTALL a new fuel tank pressure sensor. REFER to Fuel Tank Pressure Sensor in this section. 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. Test Step Result / Action to Take
NOTE:
Condition P1450 DTC set: more than - 1.79 kPa (-7.2 inches H
2 O) over 30 seconds. C1 CHECK FOR VISUAL CAUSES OF EXCESSIVE
FUEL TANK VACUUM z
Check for kinks or bends in the fuel vapor hoses
and tubes.
z Visually check the EVAP canister inlet port,
canister vent solenoid filter or outlet hose for
contamination or foreign material.
z Check the canister vent solenoid for blockage or
contamination.
z Is a concern with a hose, tube, connection or
component visually evident? Yes
REMOVE any contamination or foreign
material around fuel vapor hoses and
tubes. REPAIR the hoses, tubes or
components as necessary. After all
visual concerns are repaired, GO to
C2
.
No
GO to C2 .
C2 CHECK FOR BLOCKAGE BETWEEN EVAP
TEST PORT AND CANISTER VENT SOLENOID z
Disconnect and plug the EVAP return tube at the
intake manifold.
z Connect the Evaporative Emissions System Leak
Tester to the EVAP test port. Yes
GO to
C3 .
No Klj . 10 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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Test Step Result / Action to Take
D1 TEST FOR FUEL TANK PRESSURE SENSOR
OPERATION z
Key in OFF position.
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
GO to
D2 .
No
GO to D3 .
D2 TEST FOR BLOCKAGE IN VENTING PORTION
OF EVAP SYSTEM z
Open the canister vent solenoid by selecting the
STOP button on the scan tool.
z Does the pressure drop immediately? Yes
CARRY OUT the evaporative
emission repair verification drive
cycle. REFER to
Evaporative Emission Repair Verification Drive
Cycle in this section.
No
GO to D7 .
D3 TEST FOR FUEL TANK PRESSURE SENSOR
OPERATION z
Connect the Evaporative Emission System Leak
Tester to the evaporative emission test port.
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
GO to
D4 .
No
REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED)
manual. D4 TEST TO DETERMINE BLOCKAGE LOCATION
z
Open the canister vent solenoid.
z Does the pressure drop immediately? Yes
GO to
D5 .
No
GO to D7 .
D5 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. Klj . 12 ba
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No
GO to
D6 .
D6 TEST FOR BLOCKAGE IN FUEL FILLER TUBE
ASSEMBLY z
Disconnect the tank vapor recirculation tube from
the fuel filler pipe and plug both openings.
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? 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
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. D7 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 D8 .
D8 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
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 Klj . 13 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 Repair
Verification Drive Cycle in this
section.
No
GO to D9 .
D9 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.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? 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
the evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
GO to D10 .
D10 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
GO to D11 .
D11 TEST FOR BLOCKAGE IN CANISTER VENT
SOLENOID z
Disconnect the canister vent solenoid from the
evaporative emissions canister. Refer to
Evaporative Emission Canister Vent Solenoid in
this section. Yes
INSTALL a new canister vent
solenoid. REFER to
Evaporative Emission Canister Vent Solenoid in Klj . 14 ba
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