Visually inspect the fuel filler cap for damage.
Is the fuel filler cap damaged?
Yes
INSTALL a new fuel filler cap. GO to
A4
.
No
GO to
A4
.
A4 CHECK FOR SMALL LEAKS AT THE FUEL FILLER
CAP AND EVAP TEST PORT
Connect the Evaporative Emission System Leak
Tester to the fuel filler pipe.
Key in ON position.
Close the canister vent solenoid. Refer to
Canister
Vent Solenoid Closing Procedure
in this section.
Pressurize the EVAP system to 3.48 kPa (14 inches
H
2
O).
Using the ultrasonic leak detector, check the fuel
filler cap and EVAP test port for leaks.
Is a leak detected?
Yes
REPAIR or INSTALL new components as necessary. GO to
A5
.
No
INSTALL the fuel filler cap. 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 emissions repair verification drive cycle. REFER to
Evaporative
Emission Repair Verification Drive Cycle
in this section.
A5 CHECK FOR CONCERN OTHER THAN THE FUEL
FILLER CAP
Refer to previous test results.
Did the system pass the evaporative emission
system leak test carried out in pinpoint test Step
A2?
Yes
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.
No
INSTALL the fuel filler cap. GO to
A6
.
A6 CHECK FOR SMALL LEAK WITH TESTER SET AT
FILL POSITION
Connect the Evaporative Emission System Leak
Tester to the EVAP test port.
Key in ON position.
Close the canister vent solenoid. Refer to
Canister
Vent Solenoid Closing Procedure
in this section.
Turn the selector on the Evaporative Emission
System Leak Tester to the FILL position.
Pressurize the EVAP system to 3.48 kPa (14 inches
H
2
O).
Does the pressure on the EVAP system hold
between 3.43 kPa and 3.53 kPa (13.80 inches and
14.20 inches H
2
O)?
Yes
GO to
A7
.
No
DISCONTINUE pressurizing the system. GO to
A8
.
A7 CHECK FOR LEAKS IN THE COMPLETE EVAP
SYSTEM
Connect the Evaporative Emission System Leak
Tester to the EVAP test port.
Key in ON position.
Close the canister vent solenoid. Refer to
Canister
Vent Solenoid Closing Procedure
in this section.
Pressurize the EVAP system to 3.48 kPa (14 inches
H
2
O).
Using the ultrasonic leak detector, check the
following EVAP system locations:
EVAP return tube to EVAP canister purge
valve
EVAP canister purge valve to EVAP canister
— canister vent solenoid assembly
EVAP canisters — canister vent solenoid
assembly to fuel tank
fuel filler cap and fuel filler pipe
Is a leak detected at EVAP return tube, EVAP
canister purge outlet tube or EVAP canister tube
or associated hose?
Yes
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 emissions repair verification drive cycle.
REFER to
Evaporative Emission Repair Verification Drive Cycle
in this section.
No
DISCONTINUE pressurizing the system. GO to
A8
.
A8 CHECK FOR SMALL LEAK FROM THE EVAP
RETURN TUBE TO THE EVAP CANISTER
Disconnect the fuel tank vapor tube (9G332) at the
fuel vapor tee. Plug the opening in the tee.
Connect the Evaporative Emission System Leak
Tester to the EVAP test port.
Key in ON position.
Close the canister vent solenoid. Refer to
Canister
Vent Solenoid Closing Procedure
in this section.
Pressurize the EVAP system to 3.48 kPa (14 inches
H
2
O).
Using the ultrasonic leak detector, check the EVAP
system from the intake manifold to the EVAP
canister vent solenoid.
Is a leak detected?
Yes
REPAIR or INSTALL new components as necessary. REPEAT Step A6 to verify the repair. GO to
A9
.
No
OPEN the canister vent solenoid. GO to
A9
.
A9 CHECK FOR SMALL LEAK BETWEEN FUEL TANK
VAPOR TUBE (9C047) AND FUEL TANK FILLER PIPE
Connect the Evaporative Emission System Leak
Tester to the fuel filler pipe.
Transfer the plug from the fuel vapor tee to the fuel
tank vapor tube (9C047).
Yes
REPAIR or INSTALL new components as necessary.
GO to
A10
.
Page 4 of 8
2004 Freestar/Monterey Workshop Manual
10/9/2010
http://www.fordtechservice.dealerconnection.com/pubs/content/~WS4W/~MUS~LEN/20/...
