Ford F150 Pickup. Instruction — part 1594

1. Most OBD-II monitors will complete more readily using a steady foot driving style during cruise or

acceleration modes. Operating throttle in a smooth fashion will minimize time necessary for monitor
completion.

2. Fuel tank level should be between 1/2 and 3/4 full, with 3/4 full being most desirable.

3. Evaporative monitor can only operate during 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.

Drive Cycle Preparation

4) Install scan tool to Data Link Connector (DLC). Turn ignition switch to ON position. Cycle ignition
switch to OFF position, then back to ON position. Using scan tool, select appropriate vehicle and engine
qualifier. Clear all DTCs and perform PCM RESET PROCEDURE under CLEARING CODES under
SELF-DIAGNOSTIC SYSTEM.

5) Using scan tool, access and monitor ECT, EVAPDC, FLI (if available), and TP MODE PIDs from
PID/DATA MONITOR & RECORD menu, press "Trigger" to select each PID, then press "Start".

6) Start engine and allow to idle. DO NOT allow ignition switch to return to OFF position.

Preparation For Monitor Entry

7) Allow engine to idle for 15 seconds. Drive vehicle at 40 MPH until ECT PID is at least 170°F (76.7°
C).

8) If IAT PID is more than 40°F (4.4°C) and less than 100°F (37.8°C), go to next step. If not, continue
with following steps, but note that step 13) EVAP Monitor By-pass portion of drive cycle will be required
to by-pass EVAP monitor and clear DTC P1000.

9) Drive vehicle at 40 MPH for 60 seconds.

NOTE:

For best results, follow each of the following steps as accurately as possible.

NOTE:

This step by-passes engine soak timer and resets OBD-II monitor status.

WARNING:

Strict observance of posted speed limits and attention to driving
conditions are mandatory when proceeding through drive cycle.

NOTE:

This step allows engine warm-up and provides Intake Air Temperature
(IAT) input to PCM.

NOTE:

This step executes Heated Oxygen Sensor (HO2S) monitor.

NOTE:

This step executes EVAP monitor if IAT is more than 40°F (4.4°C) and less
than 100°F (37.8°C).

2003 Ford Pickup F150

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

10) Drive vehicle at 45-65 MPH for 10 minutes.

11) Bring vehicle to a stop. Allow engine to idle with transmission in Drive (A/T) or Neutral (M/T) for
two minutes.

Pending DTC & EVAP Monitor By-Pass Check

12) Using scan tool, check for pending DTCs. Service pending DTCs as necessary. Rerun any incomplete
monitor.

EVAP Monitor By-Pass

13) Park vehicle for a minimum of eight hours. Repeat steps 5)-12) .

TEST A: DTC P0442, P0456 OR P0457: SMALL LEAK DETECTED IN EVAP SYSTEM

Diagnostic Aids

Perform this test only when directed by QUICK TEST. DTC P0442 will set when EVAP control system
monitor fails when PCM detects one of the following from EVAP system:

z

Less Than 2.5 in. H2O (.625 kPa) Bleed-Up In 15 Seconds At 75 Percent Fuel Fill

z

Vapor Generation Limit; More Than 2.5 in. H2O (.625 kPa) In 120 Seconds

NOTE:

To initiate monitor, TP MODE should equal PT, EVAPDC must be more
than 75 percent, and FLI must be 15-85 percent.

NOTE:

Avoid sharp turns and hills.

NOTE:

This step executes ISC portion of Secondary Air/CCM.

NOTE:

This determines if a pending DTC is preventing the clearing of DTC P1000.

NOTE:

If EVAP monitor is not complete and IAT was less than 40°F (4.4°C) or
more than 100°F (37.8°C) temperature range in step 8) , or altitude is above
8000 feet, step 13) EVAP Monitor By-pass must be performed.

NOTE:

This step allows by-pass counter to increment to two. DO NOT repeat step
4) .

NOTE:

After each service or repair procedure has been completed, reconnect all
components and perform EVAPORATIVE EMISSION REPAIR VERIFICATION
DRIVE CYCLE. Clear DTCs and repeat QUICK TEST procedures to ensure all
EEC-V systems are working properly and DTCs are no longer present.

2003 Ford Pickup F150

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

DTC P0456 will set when a fuel vapor leak from an opening as small as 0.020" (0.508 mm).

If DTC P0457 is set, check for missing or leaking fuel filler cap.

F150 & Focus

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, EVAP canister and fuel vapor vent valve, and between fuel
vapor control valve tube to fuel tank 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 perform EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE.

2) Check EVAP Test Port For Small System Leaks

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

Connect Evaporative Emissions System Leak Tester (134-00056) to EVAP test port. EVAP test port is
located on EVAP canister purge outlet tube near canister purge valve. 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 fuel filler cap is leaking, replace fuel filler cap. If EVAP test port is leaking and test port is part of
EVAP canister purge valve, replace canister purge valve. If EVAP test port is leaking and test port is not
part of EVAP canister purge valve, replace EVAP test port. If leak is other than fuel filler cap or EVAP
test port, go to next step. If no leak is detected, reinstall fuel filler cap and perform

EVAPORATIVE

EMISSION REPAIR VERIFICATION DRIVE CYCLE

.

4) 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. Turn ignition switch to ON position. Perform EVAPORATIVE
EMISSIONS SYSTEM LEAK TEST. If EVAP system holds pressure between 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 6).

5) Check For Small Leaks In Complete EVAP System

Access EVAP canister vent solenoid and fuel tank assembly. Ensure evaporative emissions system leak
tester is connected to EVAP test port. Close canister vent solenoid. See CANISTER VENT SOLENOID

2003 Ford Pickup F150

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

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 leak is detected at any location, repair or replace component as necessary. If no leak is detected at any
location, release pressure from EVAP system and go to next step.

6) Check For Small Leak Between EVAP Return Tube & EVAP Canister

Disconnect EVAP canister purge outlet tube at fuel vapor connection between EVAP canister purge valve
and EVAP canister. Plug opening at EVAP canister purge outlet tube. 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 plugged end of
EVAP canister purge outlet tube. If no leak is detected, go to next step. If leak is detected, repair or
replace component as necessary. Repeat step 6) to verify repair. If leak is no longer present, go to next
step. If leak is still present, repair or replace component as necessary.

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

Connect evaporative emission system leak tester to fuel filler pipe. Plug open end of fuel vapor
connection. Turn ignition switch to ON position. 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 EVAP canister tube to fuel tank for leaks. Check fuel tank pressure
sensor, fuel vapor control valve, fuel vapor control valve tube and fuel filler pipe. If no leak is detected,
go to next step. If leak is detected, repair or replace component as necessary. Repeat step 7) to verify
repair. If leak is no longer present, go to next step. If leak is still present, repair or replace component as
necessary.

8) Check EVAP System At Fuel Filler Pipe

Reconnect all disconnected fittings. Perform EVAPORATIVE EMISSIONS SYSTEM LEAK TEST.
If EVAP system passes leak test, perform EVAPORATIVE EMISSION REPAIR VERIFICATION
DRIVE CYCLE. If system did not pass, repair or replace component as necessary. Repeat step 8) to
verify repair. Perform EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE.

Crown Victoria, Grand Marquis, Marauder, Mustang, Town Car & ZX2

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

2003 Ford Pickup F150

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