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Pinpoint Test D: Hiss When Opening Fuel Cap Or Unable To Refuel Vehicle

WARNING: This page is about a different car, the 2004 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
  1. D1 TEST FOR FUEL TANK PRESSURE SENSOR OPERATION 
    • 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 .
    • Pressurize the EVAP system to 3.48 kPa (14 inches H2O).
    • Is the FTP (FTP V) PID reading 3.11 kPa to 3.86 kPa (12.5 to 15.5 inches H2O) (4.22 to 4.90 volts)? 
      1. Yes  : GO to D2.
      2. No  : GO to  D3.
  2. D2 TEST FOR BLOCKAGE IN VENTING PORTION OF EVAP SYSTEM 
  3. D3 TEST FOR BLOCKAGE IN FUEL FILLER PIPE 
    • Connect the Evaporative Emission System Leak Tester to the fuel filler pipe.
    • Disconnect the fuel filler pipe hose from the fuel tank.
    • Pressurize the EVAP system to (3.48 kPa) (14 inches H2O).
    • Does the pressure drop immediately? 
      1. Yes  : GO to D4.
      2. No  : INSTALL a new fuel filler pipe assembly. REFER to FUEL TANK AND FILLER PIPE . CARRY OUT the evaporative emission system leak test. REFER to EVAPORATIVE EMISSION SYSTEM LEAK TEST . If the system passes the leak test, CARRY OUT the evaporative emission repair verification drive cycle. REFER to EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE .
  4. D4 TEST FOR PINCHED FUEL VAPOR CONTROL VALVE TUBE 
    • Reconnect the fuel filler pipe hose to the fuel tank.
    • Lower the fuel tank about 19 mm (0.76 in).
    • Connect the Evaporative Emission System Leak Tester to the fuel filler pipe.
    • Close the canister vent solenoid. Refer to CANISTER VENT SOLENOID CLOSING PROCEDURE .
    • Pressurize the EVAP system to 3.48 kPa (14 inches H2O).
    • Is the FTP (FTP V) PID reading 3.11 kPa to 3.86 kPa (12.5 to 15.5 inches H2O) (4.22 to 4.90 volts)? 
      1. Yes  : GO to  D2.
      2. No  : Fuel vapor control valve tube or fuel tank vapor control valve is blocked. REMOVE the fuel tank assembly. REFER to FUEL TANK AND FILLER PIPE . REMOVE the fuel vapor control tube from the tank and INSPECT it for any blockages or kinks. If the fuel vapor control tube is faulty, INSTALL a new one. If the vapor control tube is not restricted, INSTALL a new fuel tank assembly. CARRY OUT the evaporative emission system leak test. REFER to EVAPORATIVE EMISSION SYSTEM LEAK TEST . If the system passes the leak test, CARRY OUT the evaporative emission repair verification drive cycle. REFER to EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE .
  5. D5 ISOLATE LOCATION OF BLOCKAGE 
    • Disconnect the fuel vapor control valve tube assembly from the EVAP canister purge outlet tube.
      Fig 1: Identifying Fuel Vapor Control Valve Tube-To-EVAP Canister Purge Outlet Tube
      G03202074Courtesy of FORD MOTOR CO.
    • Pressurize the EVAP system to 3.48 kPa (14 inches H2O).
    • Does the pressure drop immediately? 
      1. Yes  : GO to D6.
      2. No  : Fuel vapor control valve tube or fuel tank vapor control valve is blocked. REMOVE the fuel tank assembly. REFER to FUEL TANK AND FILLER PIPE . REMOVE the vapor control tube from the tank and INSPECT it for any blockage or kinks. If the fuel vapor control tube is faulty, INSTALL a new one. If the fuel vapor control tube is not restricted, INSTALL a new fuel tank assembly. CARRY OUT the evaporative emission system leak test. REFER to EVAPORATIVE EMISSION SYSTEM LEAK TEST . If the system passes the leak test, CARRY OUT the evaporative emission repair verification drive cycle. REFER to EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE .
  6. D6 TEST FOR BLOCKAGE IN CANISTER VENT SOLENOID 
    • Reconnect the fuel vapor control valve tube assembly to the EVAP canister purge outlet tube.
    • Lower the differential to access the canister vent solenoid as necessary. Refer to DRIVELINE SYSTEM .
    • Disconnect the canister vent solenoid from the canister vent solenoid hose.
      Fig 2: Locating Canister Vent Solenoid Hose
      G03202075Courtesy of FORD MOTOR CO.
    • Pressurize the EVAP system to 3.48 kPa (14 inches H2O).
    • Does the pressure drop immediately? 
      1. Yes  : INSTALL a new canister vent solenoid. REFER to EVAPORATIVE EMISSION CANISTER VENT SOLENOID . RECONNECT all components. CARRY OUT the evaporative emission system leak test. REFER to EVAPORATIVE EMISSION SYSTEM LEAK TEST . If the system passes the leak test, CARRY OUT the evaporative emission repair verification drive cycle. REFER to EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE .
      2. No  : GO to D7.
  7. D7 TEST FOR BLOCKAGE IN THE CANISTER VENT SOLENOID HOSE 
    • Reinstall the differential. Refer to DRIVELINE SYSTEM .
    • Remove the rear subframe to access the EVAP canister with bracket assembly.
    • Lower the EVAP canister with bracket assembly.
    • Disconnect the canister vent solenoid hose from the 1.0L EVAP canister.
      Fig 3: Locating Canister Vent Solenoid Hose
      G03202076Courtesy of FORD MOTOR CO.
    • Pressurize the EVAP system to 3.48 kPa (14 inches H2O).
    • Does the pressure drop immediately? 
      1. Yes  : INSTALL a new canister vent solenoid hose. RECONNECT all components. CARRY OUT the evaporative emission system leak test. REFER to EVAPORATIVE EMISSION SYSTEM LEAK TEST . If the system passes the leak test, CARRY OUT the evaporative emission repair verification drive cycle. REFER to EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE .
      2. No  : GO to D8.
  8. D8 TEST FOR BLOCKAGE IN 1.0L EVAP CANISTER 
    • Disconnect the fuel vapor storage canister inlet tube from the 1.0L EVAP canister.
      Fig 4: Locating Fuel Vapor Storage Canister Inlet Tube-To-1.0L EVAP Canister
      G03202077Courtesy of FORD MOTOR CO.
    • Pressurize the EVAP system to 3.48 kPa (14 inches H2O).
    • Does the pressure drop immediately? 
      1. Yes  : INSTALL a new 1.0L EVAP canister. RECONNECT all components. CARRY OUT the evaporative emission system leak test. REFER to EVAPORATIVE EMISSION SYSTEM LEAK TEST . If the system passes the leak test, CARRY OUT the evaporative emission repair verification drive cycle. REFER to EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE .
      2. No  : GO to D9.
  9. D9 TEST FOR BLOCKAGE IN FUEL VAPOR STORAGE CANISTER INLET TUBE 
    • Disconnect the fuel vapor storage canister inlet tube from the 2.0L EVAP canister.
      Fig 5: Locating Fuel Vapor Storage Canister Inlet Tube-To-2.0L EVAP Canister
      G03202078Courtesy of FORD MOTOR CO.
    • Pressurize the EVAP system to 3.48 kPa (14 inches H2O).
    • Does the pressure drop immediately? 
      1. Yes  : INSTALL a new fuel vapor storage canister inlet tube. RECONNECT all components. CARRY OUT the evaporative emission system leak test. REFER to EVAPORATIVE EMISSION SYSTEM LEAK TEST . If the system passes the leak test, CARRY OUT the evaporative emission repair verification drive cycle. REFER to EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE .
      2. No  : GO to D10.
  10. D10 TEST FOR BLOCKAGE IN 2.0L EVAP CANISTER 
    • Disconnect the EVAP canister purge outlet tube from the 2.0L EVAP canister.
      Fig 6: Locating EVAP Canister Purge Outlet Tube-To-2.0L EVAP canister
      G03202079Courtesy of FORD MOTOR CO.
    • Pressurize the EVAP system to 3.48 kPa (14 inches H2O).
    • Does the pressure drop immediately? 
      1. Yes  : INSTALL a new 2.0L EVAP canister. RECONNECT all components. CARRY OUT the evaporative emission system leak test. REFER to EVAPORATIVE EMISSION SYSTEM LEAK TEST . If the system passes the leak test, CARRY OUT the evaporative emission repair verification drive cycle. REFER to EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE .
      2. No  : INSTALL a new EVAP canister purge outlet tube. RECONNECT all components. CARRY OUT the evaporative emission system leak test. REFER to EVAPORATIVE EMISSION SYSTEM LEAK TEST . If the system passes the leak test, CARRY OUT the evaporative emission repair verification drive cycle. REFER to EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE .
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