Ford F150 Pickup. Instruction — part 1596

Disconnect and plug EVAP emission return tube at intake manifold. Perform EVAPORATIVE
EMISSIONS SYSTEM LEAK TEST. If EVAP system does not pass leak test, go to step 4). If system
passes leak test, go to next step.

3) Visually Inspect Fuel Filler Cap

Visually inspect fuel filler cap for damage. If fuel filler cap is okay, go to next step. If fuel filler cap is
damaged, replace fuel filler cap and go to next step.

4) Check For Small Leaks At Fuel Filler Cap & EVAP Test Port

Connect Evaporative Emissions System Leak Tester (134-00056) to fuel filler pipe. Close canister vent
solenoid. See CANISTER VENT SOLENOID CLOSING PROCEDURE. Pressurize EVAP system to
14 in. H2O (3.48 kPa). While system is under pressure, use ultrasonic leak detector to check fuel filler
cap and EVAP test port for leaks. If a leak is detected, repair or replace components as necessary and go
to next step. If no leak is detected, reinstall fuel filler cap and perform EVAPORATIVE EMISSIONS
SYSTEM LEAK TEST. When system passes, perform EVAPORATIVE EMISSION REPAIR
VERIFICATION DRIVE CYCLE.

5) Check For Concern Other Than Fuel Filler Cap

Refer to previous test results. If EVAP system did not pass EVAPORATIVE EMISSIONS SYSTEM
LEAK TEST performed in step 2), go to next step. If EVAP system passed EVAPORATIVE
EMISSIONS SYSTEM LEAK TEST performed in step 2), repeat EVAPORATIVE EMISSIONS
SYSTEM LEAK TEST. If system now passes leak test, perform EVAPORATIVE EMISSION
REPAIR VERIFICATION DRIVE CYCLE.

6) Check For Small Leak With Tester Set At Fill Position

Connect evaporative emissions system leak tester to EVAP test port. Close canister vent solenoid. See
CANISTER VENT SOLENOID CLOSING PROCEDURE. Set selector on evaporative emissions
system leak tester to FILL position. Pressurize EVAP system to 14 in. H2O (3.48 kPa). If EVAP system
pressure is 13.80-14.20 in. H2O (3.43-3.53 kPa), go to next step. If system does not hold pressure within
specification, release pressure in EVAP system and go to step 8).

7) Check For Leaks In Complete EVAP System

Ensure evaporative emissions system leak tester is connected to EVAP test port. Close canister vent
solenoid. See CANISTER VENT SOLENOID CLOSING PROCEDURE. Pressurize EVAP system to
14 in. H2O (3.48 kPa). While system is under pressure, use ultrasonic leak detector to check the
following EVAP system locations:

z

EVAP Return Tube To EVAP Canister Purge Valve

z

EVAP Canister Purge Valve To EVAP Canister (Canister Vent Solenoid Assembly)

z

EVAP Canister (Canister Vent Solenoid Assembly) To Fuel Tank

z

Fuel Filler Cap & Fuel Filler Tube

z

EVAP Vapor Line Connections At Fuel Tank

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline

If no leak is detected at any location, release pressure from EVAP system and go to next step. If leak is
detected at any location, repair or replace component as necessary. Perform EVAPORATIVE
EMISSIONS SYSTEM LEAK TEST. When system passes, perform EVAPORATIVE EMISSION
REPAIR VERIFICATION DRIVE CYCLE.

8) Check For Small Leak Between EVAP Return Tube To EVAP Canister

Disconnect fuel tank vapor tube at fuel tank locations and plug openings in tubes. Connect evaporative
emission system leak tester to EVAP test port. Close canister vent solenoid. See CANISTER VENT
SOLENOID CLOSING PROCEDURE. Pressurize EVAP system to 14 in. H2O (3.48 kPa). While
system is under pressure, use ultrasonic leak detector to check EVAP system from intake manifold to
EVAP canister vent solenoid. If no leak is detected, open canister vent solenoid and go to next step. If
leak is detected, repair or replace component as necessary. Repeat step 6) to verify repair and go to next
step.

9) Check For Small Leak Between EVAP Canister & Fuel Filler Pipe

Connect evaporative emission system leak tester to fuel filler pipe. Plug fuel vapor vent valve ports on
fuel tank. Set selector on evaporative emissions system leak tester to FILL position. Pressurize EVAP
system to 14 in. H2O (3.48 kPa). While system is under pressure, use ultrasonic leak detector to check
fuel tank vapor tube to fuel tank for leaks. Check fuel tank pressure sensor, fuel tank vapor tube, fuel tank
module and connections, fuel tank welded joints and fuel filler pipe. If no leak is detected, perform
EVAPORATIVE EMISSIONS SYSTEM LEAK TEST. If EVAP system passes leak test, perform
EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE. If any leak is detected,
repair or replace component as necessary.

Sable & Taurus

1) Visually Inspect Components For Small Leaks

Check for presence of fuel filler cap, but DO NOT tighten or check for proper installation at this time.
Ensure canister vent solenoid is fully seated on EVAP canister. Check EVAP hoses between EVAP
canister and EVAP canister purge valve, fuel vapor control valve tube and fuel tank, and EVAP canister
and fuel vapor vent valve for cuts or loose connections. Check fuel filler pipe for damage. If no concerns
were found, go to next step. If concern was found, repair or replace component as necessary and go to
next step.

2) Check EVAP Test Port For Small System Leaks

Disconnect and plug EVAP emission return tube at intake manifold. Perform EVAPORATIVE
EMISSIONS SYSTEM LEAK TEST. If EVAP system does not pass leak test, go to step 4). If system
passes leak test, go to next step.

3) Visually Inspect Fuel Filler Cap

Visually inspect fuel filler cap for damage. If fuel filler cap is okay, go to next step. If fuel filler cap is
damaged, replace fuel filler cap and go to next step.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline

4) Check For Small Leaks At Fuel Filler Cap & EVAP Test Port

Connect Evaporative Emissions System Leak Tester (134-00056) to fuel filler pipe. Close canister vent
solenoid. See CANISTER VENT SOLENOID CLOSING PROCEDURE. Pressurize EVAP system to
14 in. H2O (3.48 kPa). While system is under pressure, use ultrasonic leak detector to check fuel filler
cap and EVAP test port for leaks. If a leak is detected, repair or replace components as necessary and go
to next step. If no leak is detected, reinstall fuel filler cap and perform EVAPORATIVE EMISSIONS
SYSTEM LEAK TEST. When system passes, perform EVAPORATIVE EMISSION REPAIR
VERIFICATION DRIVE CYCLE.

5) Check For Concern Other Than Fuel Filler Cap

Refer to previous test results. If EVAP system did not pass EVAPORATIVE EMISSIONS SYSTEM
LEAK TEST performed in step 2), go to next step. If EVAP system passed EVAPORATIVE
EMISSIONS SYSTEM LEAK TEST performed in step 2), repeat EVAPORATIVE EMISSIONS
SYSTEM LEAK TEST. If system now passes leak test, perform EVAPORATIVE EMISSION
REPAIR VERIFICATION DRIVE CYCLE.

6) Check For Small Leak With Tester Set At Fill Position

Connect evaporative emissions system leak tester to EVAP test port. Close canister vent solenoid. See
CANISTER VENT SOLENOID CLOSING PROCEDURE. Set selector on evaporative emissions
system leak tester to FILL position. Pressurize EVAP system to 14 in. H2O (3.48 kPa). If EVAP system
pressure is 13.80-14.20 in. H2O (3.43-3.53 kPa), go to next step. If system does not hold pressure within
specification, release pressure in EVAP system and go to step 8).

7) Check For Leaks In Complete EVAP System

Ensure evaporative emissions system leak tester is connected to EVAP test port. Close canister vent
solenoid. See CANISTER VENT SOLENOID CLOSING PROCEDURE. Pressurize EVAP system to
14 in. H2O (3.48 kPa). While system is under pressure, use ultrasonic leak detector to check the
following EVAP system locations:

z

EVAP Return Tube To EVAP Canister Purge Valve

z

EVAP Canister Purge Valve To EVAP Canister (Canister Vent Solenoid Assembly)

z

EVAP Canister (Canister Vent Solenoid Assembly) To Fuel Tank

z

Fuel Filler Cap & Fuel Filler Tube

If no leak is detected at any location, release pressure from EVAP system and go to next step. If a leak is
detected at any location, repair or replace component as necessary. Perform EVAPORATIVE
EMISSIONS SYSTEM LEAK TEST. When system passes, perform EVAPORATIVE EMISSION
REPAIR VERIFICATION DRIVE CYCLE.

8) Check For Small Leak Between EVAP Return Tube To EVAP Canister

Disconnect fuel vapor valve tube from EVAP canister. Plug opening in vapor tube leading to EVAP
canister. Connect evaporative emission system leak tester to EVAP test port. Close canister vent solenoid.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline

See CANISTER VENT SOLENOID CLOSING PROCEDURE. Pressurize EVAP system to 14 in.
H2O (3.48 kPa). While system is under pressure, use ultrasonic leak detector to check EVAP system from
intake manifold to EVAP canister purge outlet tube. If no leak is detected, open canister vent solenoid
and go to next step. If leak is detected, repair or replace component as necessary. Repeat step 6) to verify
repair and go to next step.

9) Check For Small Leak Between Fuel Vapor Valve Tube & Fuel Filler Pipe

Connect evaporative emission system leak tester to fuel filler pipe. Transfer plug from vapor tube leading
to EVAP canister to fuel vapor valve tube. Set selector on evaporative emissions system leak tester to
FILL position. Pressurize EVAP system to 14 in. H2O (3.48 kPa). While system is under pressure, use
ultrasonic leak detector to check fuel tank vapor tube to fuel tank for leaks. Check fuel tank pressure
sensor, fuel vapor valve tube and fuel filler pipe. If no leak is detected, go to next step. If any leak is
detected, repair or replace component as necessary and go to next step.

10) Check EVAP System At Fuel Filler Pipe

Reconnect fuel vapor valve tube to EVAP canister. Perform EVAPORATIVE EMISSIONS SYSTEM
LEAK TEST. If EVAP system passes leak test, perform EVAPORATIVE EMISSION REPAIR
VERIFICATION DRIVE CYCLE. If EVAP system did not pass leak test, repeat step 6).

All Others

1) Visually Inspect Components For Small Leaks

Check for presence of fuel filler cap, but DO NOT tighten or check for proper installation at this time.
Ensure canister vent solenoid is fully seated on EVAP canister. Check EVAP hoses between EVAP
canister and EVAP canister purge valve and EVAP canister and fuel vapor vent valve for cuts or loose
connections. Check fuel filler pipe for damage. If no concerns were found, go to next step. If concern was
found, repair or replace component as necessary and go to next step.

2) Check EVAP Test Port For Small System Leaks

Disconnect and plug EVAP emission return tube at intake manifold. Perform EVAPORATIVE
EMISSIONS SYSTEM LEAK TEST. If EVAP system does not pass leak test, go to step 4). If system
passes leak test, go to next step.

3) Visually Inspect Fuel Filler Cap

Visually inspect fuel filler cap for damage. If fuel filler cap is okay, go to next step. If fuel filler cap is
damaged, replace fuel filler cap and go to next step.

4) Check For Small Leaks At Fuel Filler Cap & EVAP Test Port

Connect Evaporative Emissions System Leak Tester (134-00056) to fuel filler pipe. Close canister vent
solenoid. See CANISTER VENT SOLENOID CLOSING PROCEDURE. Pressurize EVAP system to
14 in. H2O (3.48 kPa). While system is under pressure, use ultrasonic leak detector to check fuel filler

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline