NO.15 EMISSION COMPLIANCE[AJ (3.0L Duratec)]

• The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:

― Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

― Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete “BEFORE SERVICE PRECAUTION” and “AFTER SERVICE PRECAUTION” described in this manual.

(See BEFORE SERVICE PRECAUTION[AJ (3.0L Duratec)].)

(See AFTER SERVICE PRECAUTION[AJ (3.0L Duratec)].)

STEP	INSPECTION	RESULTS	ACTION
1	• Inspect the following: ― Vacuum lines for leakage or blockage ― Electrical connections ― Proper maintenance schedule followed ― Intake-air system and air cleaner element concerns: obstructions, leakage or dirtiness • Are all items normal?	Yes	Go to the next step.
No	Service if necessary. Repeat Step 1.
2	• Connect the M-MDS to the DLC–2. • Turn the ignition switch to the ON position (Engine off). • Retrieve any DTCs. • Is “PASSED” displayed?	Yes	No DTC is displayed: • Go to the next step.
No	DTC is displayed: • Go to the appropriate DTC test.
3	• Is any other drivability concern present?	Yes	Go to the appropriate symptom troubleshooting.
No	Go to the next step.
4	• Connect the M-MDS to the DLC–2. • Access the ECT PID. • Warm up engine and run it at idle. • Verify ECT PID is correct. • Is the ECT PID correct?	Yes	Go to the next step.
No	Inspect for coolant leakage. Inspect the cooling fan and operation or thermostat operation.
5	• Connect the M-MDS to DLC-2. • Warm up the engine and idle it. • Access the O2S11 and O2S21 PIDs. • Are O2S11 and O2S21 normal? ― More than 0.45V when the accelerator pedal suddenly depressed: rich condition ― Less than 0.45V during fuel cut: lean condition	Yes	Go to the next step.
No	Inspect and repair or replace the suspected front HO2S, wiring harness, connector or terminal, then go to the next step. (See FRONT HEATED OXYGEN SENSOR (HO2S) INSPECTION[AJ (3.0L Duratec)].)
6	• Perform the spark test. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION[AJ (3.0L Duratec)].) • Is the strong blue spark visible at each cylinder?	Yes	Go to the next step.
No	Repair or replace the malfunctioning part according to the spark test result.
7	• Inspect for the following ignition control system related parts: ― Spark plug (heat range) ― CMP sensor installation ― CMP sensor trigger wheel damaged (on camshaft) ― Open or short circuit on CMP sensor ― Open or short circuit between CMP sensor and PCM terminal 85 • Are all items normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning part.
8	• Install the fuel pressure gauge to fuel line. • Start the engine run it at idle. • Measure the fuel line pressure at idle. • Is the fuel line pressure correct? (See FUEL LINE PRESSURE INSPECTION[AJ (3.0L Duratec)].)	Yes	Go to the next step.
No	Zero or low: Inspect the clogged fuel line. • If normal, replace the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION[AJ (3.0L Duratec)].) High: Replace the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
9	• Remove and shake PCV valve. • Does PCV valve rattle?	Yes	Go to the next step.
No	Replace the PCV valve.
10	• Inspect for fuel saturation inside charcoal canister. • Is the excess amount of liquid fuel present in canister?	Yes	Replace the charcoal canister.
No	Inspect fuel tank vent system. go to the next step.
11	• Visually inspect the exhaust system part. • Is there any deformed exhaust system part?	Yes	Replace the suspected part.
No	Inspect the EGR system.
12	• Verify the test results. ― If normal, return to the diagnostic index to service any additional symptoms. ― If malfunction remains, inspect related Service Information and perform repair or diagnosis. • If vehicle is repaired, troubleshooting completed. • If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.

STEP

INSPECTION

RESULTS

ACTION

• Inspect the following:

― Vacuum lines for leakage or blockage

― Electrical connections

― Proper maintenance schedule followed

― Intake-air system and air cleaner element concerns: obstructions, leakage or dirtiness

• Are all items normal?

Yes

Go to the next step.

Service if necessary.

Repeat Step 1.

• Connect the M-MDS to the DLC–2.

• Turn the ignition switch to the ON position (Engine off).

• Retrieve any DTCs.

• Is “PASSED” displayed?

Yes

No DTC is displayed:

• Go to the next step.

DTC is displayed:

• Go to the appropriate DTC test.

• Is any other drivability concern present?

Yes

Go to the appropriate symptom troubleshooting.

Go to the next step.

• Connect the M-MDS to the DLC–2.

• Access the ECT PID.

• Warm up engine and run it at idle.

• Verify ECT PID is correct.

• Is the ECT PID correct?

Yes

Go to the next step.

Inspect for coolant leakage.

Inspect the cooling fan and operation or thermostat operation.

• Connect the M-MDS to DLC-2.

• Warm up the engine and idle it.

• Access the O2S11 and O2S21 PIDs.

• Are O2S11 and O2S21 normal?

― More than 0.45V when the accelerator pedal suddenly depressed: rich condition

― Less than 0.45V during fuel cut: lean condition

Yes

Go to the next step.

Inspect and repair or replace the suspected front HO2S, wiring harness, connector or terminal, then go to the next step.

(See FRONT HEATED OXYGEN SENSOR (HO2S) INSPECTION[AJ (3.0L Duratec)].)

• Perform the spark test.

(See ENGINE CONTROL SYSTEM OPERATION INSPECTION[AJ (3.0L Duratec)].)

• Is the strong blue spark visible at each cylinder?

Yes

Go to the next step.

Repair or replace the malfunctioning part according to the spark test result.

• Inspect for the following ignition control system related parts:

― Spark plug (heat range)

― CMP sensor installation

― CMP sensor trigger wheel damaged (on camshaft)

― Open or short circuit on CMP sensor

― Open or short circuit between CMP sensor and PCM terminal 85

• Are all items normal?

Yes

Go to the next step.

Repair or replace the malfunctioning part.

• Install the fuel pressure gauge to fuel line.

• Start the engine run it at idle.

• Measure the fuel line pressure at idle.

• Is the fuel line pressure correct?

(See FUEL LINE PRESSURE INSPECTION[AJ (3.0L Duratec)].)

Yes

Go to the next step.

Zero or low:

Inspect the clogged fuel line.

• If normal, replace the fuel pump unit.

(See FUEL PUMP UNIT REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)

High:

Replace the fuel pump unit.

(See FUEL PUMP UNIT REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)

• Remove and shake PCV valve.

• Does PCV valve rattle?

Yes

Go to the next step.

Replace the PCV valve.

• Inspect for fuel saturation inside charcoal canister.

• Is the excess amount of liquid fuel present in canister?

Yes

Replace the charcoal canister.

Inspect fuel tank vent system.

go to the next step.

• Visually inspect the exhaust system part.

• Is there any deformed exhaust system part?

Yes

Replace the suspected part.

Inspect the EGR system.

• Verify the test results.

― If normal, return to the diagnostic index to service any additional symptoms.

― If malfunction remains, inspect related Service Information and perform repair or diagnosis.

• If vehicle is repaired, troubleshooting completed.

• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.

15	Emission compliance
DESCRIPTION	• Emission compliance test is failed.
POSSIBLE CAUSE	• Vacuum lines leakage or blockage • Cooling system malfunction • Spark plug malfunction • Leakage from intake manifold • Erratic or no signal from CMP sensor • Inadequate fuel pressure • PCV valve malfunction or incorrect valve installation • EGR valve malfunction • Exhaust system clogging • Fuel tank ventilation system malfunction • Charcoal canister damage • Excessive carbon built up in combustion chamber • Improper air/fuel mixture ratio control operation • Bend or open circuit HO2S wiring harness • Improper engine compression • Improper valve timing Warning • The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services: ― Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. ― Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete “BEFORE SERVICE PRECAUTION” and “AFTER SERVICE PRECAUTION” described in this manual. (See BEFORE SERVICE PRECAUTION[AJ (3.0L Duratec)].) (See AFTER SERVICE PRECAUTION[AJ (3.0L Duratec)].)