1991 1999 ford explorer chilton User Manual
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Evaporative canister and hose routing on the 2.3L and 2.1L engine Click to enlarge HOW TO USE THIS BOOK COMPONENT TESTING 517
Evaporative canister and hose routing on the 3.0L engine-2.4L engine similar Click to enlarge HOW TO USE THIS BOOK 518 COMPONENT TESTING
Evaporative canister and hose routing on the 4.0L engine Click to enlarge HOW TO USE THIS BOOK COMPONENT TESTING 519
EVAP canister mounting for the 1.0L engine Click to enlarge HOW TO USE THIS BOOK 520 COMPONENT TESTING
Fuel vapor management valve mounting-1.0L engine shown, others similar Click to enlarge HOW TO USE THIS BOOK COMPONENT TESTING 521
EVAP hose routing on the 1.0L engine Click to enlarge Fuel Vapor Canister Generally, the only testing done to the vapor canister is a visual inspection. Look the canister over and replace it with a new one if there is any evidence of cracks or other damage. Do not try to check the fuel saturation of the canister by weighing it or by the intensity of the fuel odor from the canister. These methods are unreliable and inhaling gasoline fumes can be toxic. CANP Solenoid 1441-1444 MODELS Remove the CANP solenoid. 1. Using an external voltage source, apply 4-14 DC volts to the CANP solenoid electrical terminals. Then, use a hand-held vacuum pump and apply 16 in. Hg (13 kPa) vacuum to the manifold side nipple of the CANP solenoid. If the solenoid opens and allows air to freely pass through it, the solenoid is working properly. 1. 2. HOW TO USE THIS BOOK 522 COMPONENT TESTING
If the solenoid does not allow air to pass freely while energized, replace the solenoid with a new one. 2. 1441-44 MODELS Remove the CANP solenoid. 1. Measure the resistance between the two CANP terminals. If the resistance is between 30-40 ohms, proceed to the Step 3. 1. If the resistance is not between 30-40 ohms, replace the CANP solenoid. 2. 2. Attach a hand-held vacuum pump to the intake manifold vacuum side of the CANP solenoid, then apply 16 in. Hg (13 kPa) of vacuum to the solenoid. If the solenoid will not hold vacuum for at least 20 seconds replace it with a new one. 1. If the solenoid holds vacuum, proceed to Step 4. Keep the vacuum applied to the solenoid. 2. 3. Using an external voltage source, apply 4-14 DC volts to the CANP solenoid electrical terminals. If the solenoid opens and the vacuum drops, the solenoid is working properly. 1. If the solenoid does not open and the vacuum remains, replace the solenoid with a new one. 2. 4. REMOVAL & INSTALLATION Fuel Vapor Canister The fuel vapor canister is referred to as the evaporative emissions canister on 1441-44 models. Disconnect the vapor hoses from the canister. 1. Remove the mounting screws, then remove the canister. 2. To install: Position the canister in place, then install the mounting screws. 3. Attach all of the vapor hoses to the canister. 4. Fuel Vapor Valve This component is also known as the evaporative emission valve on 1441-44 models. Disconnect the negative battery cable. 1. Relieve the fuel system pressure. 2. Remove the fuel tank. 3. Remove the fuel vapor valve from the fuel tank. 4. To install: Install the fuel vapor valve into the fuel tank. 1. Install the fuel tank in the vehicle. 2. Connect the negative battery cable. 3. CANP Solenoid Disconnect the vapor hoses from the CANP solenoid. 1. Unplug the electrical connector from the CANP solenoid. 2. Remove the purge solenoid valve from the vehicle. 3. To install: HOW TO USE THIS BOOK COMPONENT TESTING 523
Install the CANP solenoid, then attach the engine wiring harness connector to the solenoid. 4. Connect the vapor hoses to the solenoid. 5. Pressure/Vacuum Relief Fuel Tank Filler Cap Unscrew the fuel filler cap. The cap has a pre-vent feature that allows the tank to vent for the first 3 /4 turn before unthreading. 1. Remove the screw retaining the fuel cap tether and remove the fuel cap. 2. To install: Position the end of the tether against its mounting boss, then install and tighten the tether screw. 3. Thread the filler cap into the fuel tank filler tube, making sure to turn it clockwise until the ratchet mechanism gives off 3 or more loud clicks. 4. Exhaust Gas Recirculation (EGR) System OPERATION The Exhaust Gas Recirculation (EGR) system is designed to reintroduce exhaust gas into the combustion chambers, thereby lowering combustion temperatures and reducing the formation of Oxides of Nitrogen (NO x). The amount of exhaust gas that is reintroduced into the combustion cycle is determined by several factors, such as: engine speed, engine vacuum, exhaust system backpressure, coolant temperature, throttle position. All EGR valves are vacuum operated. The EGR vacuum diagram for your particular vehicle is displayed on the Vehicle Emission Control Information (VECI) label. The EGR system is a Pressure Feedback EGR (PFE) or Differential PFE (DPFE) system, controlled by the Powertrain Control Module (PCM) and composed of the following components: PFE or DPFE sensor (also referred to as the backpressure transducer), EGR Vacuum Regulator (EVR) solenoid, EGR valve, and assorted hoses and tubing. HOW TO USE THIS BOOK 524 REMOVAL & INSTALLATION
Typical EGR system schematic Click to enlarge COMPONENT TESTING HOW TO USE THIS BOOK OPERATION 525
Exploded view of the EGR system and related components for the 2.3L and 2.5L engine Click to enlarge HOW TO USE THIS BOOK 526 COMPONENT TESTING