LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 2768 (Engine Controls - Pinpoint Test DX: Engine Coolant Temperature (ECT) Sensor Through Pinpoint Test HC: Fuel Delivery System - CNG, Flex-Fuel & Gasoline) >> Pinpoint Test EM: Emission Compliance >> Test Procedure

Test Procedure

WARNING: This page does not describe the selected car, but rather 30 other vehicles, including the 2004 Mercury Sable, 2004 Mercury Mountaineer, 2004 Mercury Monterey, 2004 Mercury Marauder, and 2004 Mercury Grand Marquis. However, it is still accessible from the selected car via links, so may be relevant.
  1. EM1 ANALYZE THE I/M TEST REPORT 
    • Analyze the I/M test report for data entry errors.
      • MODEL.
      • Model Year.
      • Correct calibration, if included on the report.
      • Correct test weight, if included on the report (this number is less than the vehicle's GVW).
    • Analyze the I/M test report results.
      • Identify high and low gas readings.
      • For reports that include a drive trace, identify during which mode the gas(es) failed. Be aware that if all gases were high early then decreased, the catalyst may have been cool when testing began.

    Has the I/M test report been analyzed? 

    Yes No
    GO to  EM2. Repeat test
  2. EM2 EVAP SYSTEM LEAK OR PURGE FLOW TEST (IF THESE TESTS WERE PERFORMED) 
    Yes No
    EVAP concern only
    GO to  EM22.    		 GO to  EM3.
  3. EM3 BASELINE VEHICLES 
    NOTE: Baselining the vehicle's exhaust gas readings is important so the baseline readings can be used for comparison after any repair is made.
    • Baseline the vehicle using an exhaust gas analyzer. If the vehicle must be driven, be certain any baseline drive used is repeatable. The same drive cycle will be used to verify any repair.
    • During the baseline, check for any related symptoms that may be present, such as drivability, transmission shifting or exhaust smoke concerns.

    Has the vehicle been baselined? 

    Yes No
    GO to  EM4. Repeat test
  4. EM4 SYMPTOM CHECKS 

    Are any of the following symptoms present? 

    • Transmission Concerns.
    • Idle Concerns.
    • Driveability Concerns.
    • Exhaust smoke.
    • Cooling System Concerns.
    Yes No
    Go to QT: STEP 1: PCM QUICK TEST for directions to repair the additional symptom. Also refer to the Exhaust Gas Analysis Chart Figure, at the beginning of this pinpoint test.
    After any repair,
    GO to  EM26.    		 GO to  EM5.
  5. EM5 PRELIMINARY CHECKS 
    • Perform these checks.
      • Vacuum lines (leak/blockage).
      • Electrical connections.
      • proper scheduled maintenance.
      • Ford authorized emission controls and components installed on vehicle.
      • Intake air tube and air cleaner concerns (such as obstructions, leaks, or a dirty air cleaner element).

    Are all Test checks OK? 

    Yes No
    GO to  EM6. REPAIR as necessary.
    After any repair,
    GO to  EM26.
  6. EM6 PERFORM THE PCM QUICK TEST 

    Is a fault indicated? 

    Yes No
    Follow THE QT: STEP 1: PCM QUICK TEST direction.
    After any repair,
    GO to  EM26.    		 GO to  EM7.
  7. EM7 EXCESSIVE CARBON MONOXIDE (CO) LEVELS? 

    Did the vehicle have excessive Carbon Monoxide (CO) levels? 

    Yes No
    Excessive CO levels indicate Engine Running Rich
    GO to  EM10.    		 GO to  EM8.
  8. EM8 EXCESSIVE HYDROCARBON HC LEVELS? 

    Did the vehicle have excessive Hydrocarbon HC levels? 

    Yes No
    Excessive HC with low to normal CO levels indicate Engine Running Lean
    GO to  EM16.    		 GO to  EM9.
  9. EM9 EXCESSIVE OXIDES OF NITROGEN NOX LEVELS? 

    Did the vehicle have excessive Oxides of Nitrogen NOx levels? 

    Yes No
    GO to  EM20. Verify the test step results
  10. EM10 HIGH CO LEVELS: CHECK THE HC LEVELS 

    Did the vehicle have excessive Hydrocarbon HC levels? 

    Yes No
    CHECK for issues with Engine Running Rich & Incomplete Combustion
    GO to  EM11.    		 GO to  EM12.
  11. EM11 CHECK THE SECONDARY IGNITION SYSTEM 

    Is a fault indicated? 

    Yes No
    Follow the pinpoint test direction.
    After any repair,
    GO to  EM26.    		 GO to  EM12.
  12. EM12 CHECK THE FUEL DELIVERY SYSTEM FOR CONCERNS (SUCH AS HIGH FUEL PRESSURE AND THE ABILITY TO HOLD PRESSURE) 
    • For natural gas applications:
      • FOLLOW the pinpoint test direction in test step  HB1.
    • All Others:
      • FOLLOW the pinpoint test direction in test step  HC1.

    Is a fault indicated? 

    Yes No
    Follow the pinpoint test direction.
    After any repair,
    GO to  EM26.    		 GO to  EM13.
  13. EM13 CHECK FOR VACUUM LEAKS/OBSTRUCTION IN THE PCV SYSTEM (SUCH AS OIL CAP, PCV VALVE, HOSES, CUT GROMMETS, VALVE COVER BOLT TORQUE/GASKET LEAK) 

    Is a fault indicated? 

    Yes No
    Follow the pinpoint test direction.
    After any repair,
    GO to  EM26.    		 GO to  EM14.
  14. EM14 CHECK THE EXHAUST SYSTEM 

    Is a fault indicated? 

    Yes No
    Follow the pinpoint test direction.
    After any repair,
    GO to  EM26.    		 GO to  EM15.
  15. EM15 CHECK THE BASE ENGINE 
    • Go to the appropriate ENGINE article to check for proper compression, valve train and camshaft.

    Is a fault indicated? 

    Yes No
    Refer to the appropriate ENGINE article.
    Repair as required.
    After any repair, GO to  EM26.    		 GO to  EM27.
  16. EM16 HIGH HC WITH A NORMAL TO LOW CO LEVEL 
    • CHECK the fuel delivery system for concerns:
      • For natural gas applications: FOLLOW the pinpoint test direction in test step  HB1 .
      • All Others: FOLLOW the pinpoint test direction in test step  HC1.

    Is a fault indicated? 

    Yes No
    Follow the pinpoint test direction.
    After any repair,
    GO to  EM26.    		 GO to  EM17.
  17. EM17 CHECK THE SECONDARY IGNITION 

    Is a fault indicated? 

    Yes No
    Follow the pinpoint test direction.
    After any repair,
    GO to  EM26.    		 GO to  EM18.
  18. EM18 CHECK FOR VACUUM LEAKS/OBSTRUCTION IN THE PCV SYSTEM (SUCH AS OIL CAP, PCV VALVE, HOSES, CUT GROMMETS, VALVE COVER BOLT TORQUE/GASKET LEAK) 

    Is a fault indicated? 

    Yes No
    Follow the pinpoint test direction.
    After any repair,
    GO to  EM26.    		 GO to  EM19.
  19. EM19 CHECK THE BASE ENGINE 
    • Go to the appropriate ENGINE article to check the base engine for concerns such as intake manifold leaks, improper compression, or valve train or camshaft damage.

    Is a fault indicated? 

    Yes No
    Refer to the appropriate ENGINE article.
    Repair as required.
    After any repair,
    GO to  EM26.    		 GO to  EM27.
  20. EM20 HIGH NOX WITH NORMAL TO LOW HC AND CO LEVELS: CHECK THE BASE ENGINE 
    • Go to the appropriate ENGINE article to check for base engine concerns, such as excessive carbon build up in the combustion chamber.

    Is a fault indicated? 

    Yes No
    Refer to the appropriate ENGINE article.
    Repair as necessary.
    After any repair,
    GO to  EM26.    		 GO to  EM21.
  21. EM21 ADDITIONAL CHECKS 
    • Additional Checks.
      • transmission torque converter clutch operation.
      • Cooling System Concerns (such as the aftermarket front fascia covering intake air, intake air system modifications).
      • Engine Running Lean (concerns such as vacuum leaks, low fuel pressure).

    Are all checks OK? 

    Yes No
    GO to  EM27. Repair as necessary.
    After any repair,
    GO to  EM26.
  22. EM22 EVAP SYSTEM CONCERN: PRELIMINARY CHECKS 
    • Analyze the I/M test report to determine when the concern is present. Attempt to verify the concern.
    • Preliminary Checks.
      • Fuel filler cap.
      • EVAP system lines/hoses (check for proper connections, damage or blockage).
      • Fuel vapor storage canister damage.

    Are all checks OK? 

    Yes No
    GO to  EM23. Repair as necessary.
    After any repair,
    GO to  EM25.
  23. EM23 PERFORM THE PCM QUICK TEST 

    Is a fault indicated? 

    Yes No
    Follow THE QT: STEP 1: PCM QUICK TEST direction.
    After any repair,
    GO to  EM25.    		 GO to  EM24.
  24. EM24 EVAP SYSTEM CHECK 
    • Check for system leaks.

    Is a fault indicated? 

    Yes No
    Refer to the appropriate EVAPORATIVE EMISSIONS article.
    REPAIR as necessary.
    After any repair,
    GO to  EM25.    		 Verify the test step results
    If all test steps are OK,
    GO to PINPOINT TEST Z step 1 .
    Otherwise, return to SYMPTOM CHARTS - CNG, FLEX-FUEL & GASOLINE to repair any additional symptoms.
    After any repair,
    GO to  EM25.
  25. EM25 EVAP SYSTEM REPAIR VERIFICATION 
    • Vehicle repair performed.
    • RESET the keep alive memory (KAM). REFER to RESETTING THE KEEP ALIVE MEMORY (KAM) .
    • Be aware that this will set DTC P1000 and reset the On -Board System Readiness test.
    • To relearn some basic adaptive learning (trim) values, run the engine at 2,500 RPM for 1 minute and idle the engine for 2 minutes.
    • CARRY OUT a PCM quick test to access any PCM DTCs. REFER to QT: STEP 1: PCM QUICK TEST (for test step procedure only).
    • Perform the EVAP system leak test and flow check.

    Does the vehicle pass the EVAP system leak test and flow check? 

    Yes No
    Save any repair documentation that may be required by local/federal laws.
    Return the vehicle to the customer    		 The original concern was not repaired, or another concern exists.
    GO to  EM1.
  26. EM26 REPAIR AND VERIFICATION 
    • Vehicle repair performed.
    • RESET the keep alive memory (KAM). REFER to RESETTING THE KEEP ALIVE MEMORY (KAM) . Be aware that this will set DTC P1000 and reset the On -Board System Readiness test.
    • To relearn some basic adaptive learning (trim) values, run the engine at 2,500 RPM for 1 minute and idle the engine for 2 minutes.
    • CARRY OUT a PCM quick test to access any PCM DTCs. REFER to QT: STEP 1: PCM QUICK TEST (for test step procedure only).
      • REPAIR any other DTCs as necessary.
    • Perform the baseline test using the exhaust gas analyzer.
      NOTE: If vehicle needs to be driven for the baseline, it may be necessary to drive the vehicle first up to 8 km (5 miles) to relearn some additional adaptive learning (trim) values. Also, during the baseline be certain to use the same drive mode that was used for the original baseline test.
    • For I/M 240 emission testing areas:
      • REFER to the INTRODUCTION  of this pinpoint test for information on verifying an excessive Grams Per Mile indication using a Parts Per Million (PPM) reading.
    • All Others (original gas concentrations reported in parts per million):
      • Verify gas levels are within the acceptable range.

    Are all gases within the acceptable range? 

    Yes No
    Save any repair documentation that may be required by local/federal laws.
    Return the vehicle to the customer    		 The gas level is still high, or another gas level is above the acceptable range.
    GO to  EM1.
  27. EM27 CATALYST DELTA TEMPERATURE TEST 
    • All previous testing as indicated completed.
    • Disable the AIR system, if equipped.
    • Run the engine for 2 minutes at 2,500 RPM to heat the exhaust system.
    • Key in OFF position.
    • Disconnect and ground 1 spark plug wire from each cylinder bank (for coil on plug applications, disconnect the coil connector).
    • Run the engine at approximately 1,000 RPM.
    • Disconnect the IAC valve and maintain (1,000 RPM).
    • Measure the surface temperature of both the inlet and outlet of each underbody catalytic converter using an infrared temperature probe.
    • Compare the difference in temperature between the inlet and outlet readings of each under-body catalytic converter.

    Does each catalytic converter have a difference of more than 28°C (50°F) between its inlet and outlet reading? 

    Yes No
    The catalytic converter(s) is operating correctly.
    Reconnect the spark plug wire(s), the IAC, and the AIR system (if equipped).
    CLEAR the DTCs.
    Verify the test step results
    If all test steps are OK,
    GO to Z1 .
    Otherwise, return to SYMPTOM CHARTS - CNG, FLEX-FUEL & GASOLINE to repair any additional symptoms.
    After any repair,
    GO to  EM26.    		 For the catalytic converter(s) that has less than 28 ° C (50 °F) difference, testing indicates the catalytic converter(s) is not working. REPEAT the test to verify results. If the temperature difference is still less than required, REPLACE the catalytic converter. RESTORE the vehicle
    After any repair,
    GO to  EM26.
scientia non olet · About LEMON Manuals