Evaporative Emissions Ford Five Hundred I

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Evaporative Emission System

The evaporative emission (EVAP) system

1. is equipped with an on-board refueling vapor recovery (ORVR) system.
2. prevents hydrocarbon emissions from reaching the atmosphere.
3. stores fuel vapors in the EVAP canister that are generated during vehicle operation or hot soak, or vehicle refueling, until they can be consumed by the engine.
4. routes the stored fuel vapors to the engine during engine operation.
5. is controlled by the powertrain control module (PCM) which uses various sensor inputs to calculate the desired amount of purge flow. The PCM regulates the purge flow, induced by the application of intake manifold vacuum, by varying the duty cycle applied to the EVAP canister purge valve.
6. has an EVAP test port for test purposes.

The fuel vapors are routed

1. from the fuel tank through the fill limiting vent valve and fuel vapor vent valve.
2. to the EVAP canister through a vapor tube.
3. to the engine when the EVAP canister purge valve is opened by the PCM.

The fuel tank pressure (FTP) sensor

1. monitors the pressure levels in the vapor tube prior to the fuel tank.
2. communicates the pressure reading to the PCM during the OBDII leak test.
3. is located in the fuel vapor valve tube and is serviced as part of the fuel vapor control tube assembly valve.

The EVAP canister

1. is located under the right rear of the vehicle.
2. contains activated carbon.
3. stores fuel vapor.
4. includes a fresh air transfer tube routing fresh air between the canister vent solenoid hose and the fuel tank filler door pocket.

The fuel tank filler cap

1. relieves system vacuum below 3.8 kPa (15.26 inches H 2 O).

The EVAP canister vent solenoid

1. is normally open.
2. seals the EVAP system for the inspection and maintenance (I/M 240) test and OBDII leak and pressure tests.
3. is mounted to the EVAP canister.
4. is repaired as a separate item.

The EVAP canister purge valve

1. is normally closed.
2. regulates purging of the EVAP canister.
3. is controlled by the PCM.

The fuel vapor control tube assembly valve

1. consists of the fill limiting vent valve and fuel vapor vent valve located inside the fuel tank.
2. prevents suspended liquid fuel from being drawn into the EVAP canister along with the fuel vapors.

The EVAP system monitor

1. is a self-test strategy within the PCM, which tests the integrity of the EVAP system.
2. monitors the EVAP system for leaks.
3. monitors electronic EVAP components for irrationally high or low voltages.
4. monitors for correct EVAP system operation.
5. uses negative and positive leak test methods to test and activate the EVAP system.

The EVAP test port

1. is used to connect the Evaporative Emission System Leak Tester to the EVAP system.
2. is located on the purge valve.

The EVAP Running Loss System Leak Test

1. utilizes intake manifold vacuum to test the EVAP system and involves several stages.

Refer to the INTRODUCTION - GASOLINE article .

Canister Vent Solenoid Closing Procedure

SPECIAL TOOL CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

Scheme 5

1. Connect the diagnostic tool and select the output test mode.
2. If parameter identification (PID) monitors are not active, select PIDs.
3. Select the fuel tank pressure (FTP) and the volts (V) PID for monitoring.
4. Select the ALL OFF mode.
5. Close the canister vent solenoid by pushing the START button on the diagnostic tool.

Special Tool(s)

SPECIAL TOOL CHART VACUTEC Smoke Machine Fuel Evaporative Emission System Tester 218-0002 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 6

Scheme 7

Phase 1 - Leak Verification

1. Connect the smoke machine leak tester to the evaporative emission (EVAP) canister purge valve. For additional information, refer to the manufacturer' s instructions.
2. Using the scan tool, CLOSE the canister vent solenoid. For additional information, refer to the manufacturers instructions.
3. Using the smoke machine, pressurize the EVAP system.
4. Monitor the indicator flag on the smoke machine leak tester. If the measurement is below the indicator flag, the system has passed the leak test and the test procedure is complete. If the measurement is above the indicator flag, the system has failed the leak test. Proceed to «PHASE 2»(/ford/five-hundred/i-2004-2007/remont/auxiliary-emission-control-systems/#evaporative-emissions__phase-2-system-leak-check) .

Phase 2 - System Leak Check

1. Introduce smoke from the smoke machine into the EVAP system. For additional information, refer to the manufacturer's instructions.
2. Use the halogen light provided with the smoke machine to look for smoke coming from the EVAP system. This would indicate a leak point.
3. Repair any leaks as necessary.
4. Repeat the leak test until the system passes.

SPECIAL TOOL CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

Drive Cycle Recommendations

Note. The following procedure is designed to execute and complete the evaporative emission (EVAP) 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 1/2 and 3/4 full with 3/4 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.
4. Install the diagnostic 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.
7. 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. Cruise at 64 km/h (40 mph) for 60 seconds.
10. Cruise at 72 to 104 km/h (45 to 65 mph) for 10 minutes.
11. Bring the vehicle to a stop. Idle with the transmission in DRIVE (for automatic transmission) or NEUTRAL (for manual transmission) for 2 minutes.
12. Using the diagnostic tool, check for pending codes. Conduct normal repair procedures for any pending code concerns. Rerun any incomplete monitor.
13. Park the vehicle for a minimum of 8 hours. Repeat Steps 5 through 12.

Scheme 8

1. For additional information, refer to the procedures below.

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
3. Disconnect the evaporative emission (EVAP) canister vent solenoid electrical connector.
4. Disconnect the vapor tube-to-EVAP canister quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
5. Disconnect the front vapor tube-to-dust separator.
6. Remove the 2 EVAP canister retaining nuts. To install, tighten to 9 Nm (80 lb-in).
7. Remove the 2 EVAP canister retaining bolts. To install, tighten to 9 Nm (80 lb-in).
8. Release the 3 wire harness pushpin retainers.
9. Remove the EVAP canister.
10. To install, reverse the removal procedure. Carry out a leak test. For additional information, refer to «EVAPORATIVE EMISSION SYSTEM LEAK TEST»(/ford/five-hundred/i-2004-2007/remont/auxiliary-emission-control-systems/#evaporative-emissions) . Carry out the evaporative emission repair verification drive cycle. For additional information, refer to «INTRODUCTION - GASOLINE»(/ford/five-hundred/i-2004-2007/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article .

Scheme 9

Scheme 10

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
3. Remove the rear seat lower cushion. Release the latches and pull upward on the rear lower seat cushion and remove.
4. Position the second row seats to the forward folded position.
5. Release the 2 load floor support brackets and position the load floor upward.
6. Position the third row seats into the load floor.
7. Remove the 4 load floor support-to-floor pan retaining nuts. To install, tighten to 18 Nm (13 lb-ft).
8. Remove the 2 load floor support brackets.
9. Position the rear floor carpet and any padding or insulation covering the fuel pump module and fuel level sensor aside.
10. Remove the fuel pump module access cover.
11. Disconnect the fuel vapor control tube assembly valve-to-fuel pump module quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
12. Place a suitable lifting device under the fuel tank.
13. Remove the RH rear fuel tank strap bolt. To install, tighten to 35 Nm (26 lb-ft).
14. Partially lower the RH side of the fuel tank.
15. Disconnect the fuel vapor control tube assembly valve electrical connector.
16. Disconnect the vapor tube quick connect coupling-to-fuel vapor control tube assembly valve. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
17. Disconnect the fuel vapor control tube assembly valve-to-vapor tube quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
18. Release the fuel vapor control tube assembly valve from the retainer clips on the side of the fuel tank.
19. Remove the fuel vapor control tube assembly valve.
20. To install, reverse the removal procedure. Carry out a leak test. For additional information, refer to «EVAPORATIVE EMISSION SYSTEM LEAK TEST»(/ford/five-hundred/i-2004-2007/remont/auxiliary-emission-control-systems/#evaporative-emissions) . Carry out the evaporative emission repair verification drive cycle. For additional information, refer to the «INTRODUCTION - GASOLINE»(/ford/five-hundred/i-2004-2007/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article .

Scheme 11

Scheme 12

Scheme 13

1. Remove the evaporative emission (EVAP) canister. For additional information, refer to «EVAPORATIVE EMISSION CANISTER»(/ford/five-hundred/i-2004-2007/remont/auxiliary-emission-control-systems/#evaporative-emissions) .
2. Disconnect the EVAP canister vent tube-to-dust separator hose.
3. Push the lock tab retainer to release the dust separator from the EVAP canister assembly bracket.
4. Remove the dust separator from the EVAP canister assembly bracket.
5. To install, reverse the removal procedure.

Material

MATERIAL CHART

Scheme 14

Scheme 15

1. Remove the evaporative emission (EVAP) canister. For additional information, refer to «EVAPORATIVE EMISSION CANISTER»(/ford/five-hundred/i-2004-2007/remont/auxiliary-emission-control-systems/#evaporative-emissions) .
2. Remove the EVAP canister vent tube-to-EVAP canister vent solenoid.
3. Release the EVAP canister vent solenoid from the carbon canister and remove from the EVAP canister assembly.
4. To install, reverse the removal procedure. Apply clean engine oil to the EVAP canister vent solenoid O-ring seal.

Evaporative Emission Canister Purge Valve

Scheme 16

Scheme 17

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector.
3. Disconnect the 2 vapor tube-to-EVAP canister purge valve quick connect couplings. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
4. Depress the retaining tab to release and remove the EVAP canister purge valve from the retaining bracket.
5. To install, reverse the removal procedure. Leak test the system. For additional information, refer to «EVAPORATIVE EMISSION SYSTEM LEAK TEST»(/ford/five-hundred/i-2004-2007/remont/auxiliary-emission-control-systems/#evaporative-emissions) . Carry out the evaporative emission repair verification drive cycle. For additional information, refer to the «INTRODUCTION - GASOLINE»(/ford/five-hundred/i-2004-2007/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article .

See also:
• INTRODUCTION - GASOLINE
• JACKING & LIFTING
• BATTERY, MOUNTING AND CABLES
• FUEL SYSTEM-GENERAL INFORMATION
• PHASE 2
• EVAPORATIVE EMISSION SYSTEM LEAK TEST