EM: Emissions Compliance

EM: Introduction See: EM: Emissions Compliance - Introduction

EM1 ANALYZE VEHICLE'S INSPECTION AND MAINTENANCE (I/M) TEST REPORT

• Analyze I/M test report for data entry errors:
• Correct model and year.
• Correct test weight, if included on report (this number will be less than the vehicle's GVW).
• Correct calibration, if included on report (such as Calif. or Federal).
• Analyze I/M test report results:
• Identify which gas readings are high AND which readings are low.
• 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

• GO to EM2

.

No

• REPEAT this test step.

EM2 DID THE VEHICLE FAIL ONLY AN EVAP SYSTEM LEAK TEST OR A PURGE FLOW TEST (if these tests were performed)?

Did the vehicle fail only an EVAP system leak test or purge flow test (all gases OK)?
Yes

• EVAP concern only. GO to EM35

.

No

• GO to EM3

.

EM3 BASELINE VEHICLE

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 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 driveability, transmission shifting or exhaust smoke concerns).

Has the vehicle been baselined?
Yes

• GO to EM4

.

No

• REPEAT this test step.

EM4 CHECK IF ANY OTHER SYMPTOMS ARE PRESENT

Are any of the following symptoms present?

• Driveability Concerns (including Idle or Transmission Concerns).
• Exhaust smoke.
• Cooling System Concerns (engine not operating at proper temperature).

Yes

• GO to Section 3 See: Symptom Related Diagnostic Procedures (begin at Step 1: PCM Quick Test See: QT: Step 1: PCM Quick Test) for direction to repair the

additional symptom. Also REFER to the Exhaust Gas Analysis Chart at the
beginning of this pinpoint test for additional information. After any
repair, GO to EM40
to verify repair.

No

• No other concerns present. GO to EM5

.

EM5 PRELIMINARY CHECKS

• Perform the following preliminary checks:
• Vacuum lines (leaks/blockage).
• Electrical connections.
• Proper scheduled maintenance.
• Intake air tube and air cleaner concerns (such as obstructions, leaks or dirty air cleaner element).
• Ford authorized emission controls and components installed on vehicle.

Are all checks OK?
Yes

• GO to EM6

.

No

• REPAIR as necessary. After repair, GO to EM40

to VERIFY repair.

EM6 PERFORM PCM QUICK TEST

• Complete PCM Quick Test to access any PCM DTCs (Refer to Section 3, Step 1: PCM Quick Test (for Test Step procedure only)). See: QT: Step 1: PCM Quick Test

Is a fault indicated?
Yes

• FOLLOW Section 3 See: Symptom Related Diagnostic Procedures Quick Test direction. After repair, GO to EM40

to verify repair.

No

• GO to EM7

.

EM7 CHECK CARBON MONOXIDE (CO) LEVELS

Did the vehicle have excessive CO levels?
Yes

• Excessive CO levels indicate that the engine is running rich. GO to EM15

.

No

• GO to EM8

.

EM8 CHECK HYDROCARBON (HC) LEVELS

Did the vehicle have excessive HC levels?
Yes

• Excessive HC levels with low to normal CO levels indicate that the engine is running lean. GO to EM25

.

No

• GO to EM9

.

EM9 CHECK OXIDES OF NITROGEN (NOx) LEVELS

Did the vehicle have excessive NOx levels?
Yes

• GO to EM30

.

No

• VERIFY all previous testing.

EM15 HIGH CO LEVELS: CHECK HC LEVELS

Did the vehicle have excessive HC levels?
Yes

• GO to EM16

(to check for incomplete combustion/running rich).

No

• GO to EM17

(to check for running rich).

EM16 CHECK SECONDARY IGNITION SYSTEM

• GO to JB1 See: Diagnostic Trouble Code Tests and Associated Procedures\SECTION 5: Pinpoint Tests\JB: Secondary Ignition - Pinpoint Test to check the secondary ignition system.

Is a fault indicated?
Yes

• FOLLOW Pinpoint Test direction. After repair, GO to EM40

to verify repair.

No

• GO to EM17

.

EM17 CHECK FUEL DELIVERY SYSTEM FOR CONCERNS SUCH AS HIGH FUEL PRESSURE AND ABILITY TO HOLD PRESSURE

• For Natural Gas applications:
• GO to HB1 See: HB: Natural Gas Fuel Delivery System - Pinpoint Test.
• All others:
• GO to HC1 See: Diagnostic Trouble Code Tests and Associated Procedures\SECTION 5: Pinpoint Tests\HC: Fuel Delivery System - Pinpoint Test.

Is a fault indicated?
Yes

• FOLLOW Pinpoint Test direction. After repair, GO to EM40

to verify repair.

No

• GO to EM18

.

EM18 CHECK PCV SYSTEM FOR LEAKS, STUCK VALVE, ETC.

• GO to HG1 See: Diagnostic Trouble Code Tests and Associated Procedures\SECTION 5: Pinpoint Tests\HG: Positive Crankcase Ventilation (PCV) System - Pinpoint Test to check the PCV System.

Is a fault indicated?
Yes

• FOLLOW Pinpoint Test direction. After repair, GO to EM40

to verify repair.

No

• GO to EM19

.

EM19 CHECK EXHAUST SYSTEM

• GO to HF1 See: Diagnostic Trouble Code Tests and Associated Procedures\SECTION 5: Pinpoint Tests\HF: Catalyst Efficiency Monitor and Exhaust Systems - Pinpoint Test to check the exhaust system.

Is a fault indicated?
Yes

• FOLLOW Pinpoint Test direction. After repair is performed, GO to EM40

to verify repair.

No

• GO to EM20

.

EM20 CHECK BASE ENGINE

• Go to Engine System-General Information to check for proper compression, valvetrain, camshaft, etc.

Is a fault indicated?
Yes

• REPAIR as required according to diagnostic/repair information direction. After repair, GO to EM40

to verify repair.

No

• GO to EM21

.

EM21 ADDITIONAL CHECKS

• Additional checks:
• Incorrect PCV valve.

Are all checks OK?
Yes

• GO to EM45

.

No

• REPAIR as necessary. After repair, GO to EM40

to verify repair.

EM25 HIGH HC WITH NORMAL TO LOW CO LEVEL: CHECK FUEL DELIVERY SYSTEM FOR CONCERNS SUCH AS LOW FUEL PRESSURE

• For Natural Gas applications:
• GO to HB1 See: HB: Natural Gas Fuel Delivery System - Pinpoint Test.
• All others:
• GO to HC1 See: Diagnostic Trouble Code Tests and Associated Procedures\SECTION 5: Pinpoint Tests\HC: Fuel Delivery System - Pinpoint Test.

Is a fault indicated?
Yes

• FOLLOW Pinpoint Test direction. After repair, GO to EM40

to verify repair.

No

• GO to EM26

.

EM26 CHECK SECONDARY IGNITION SYSTEM

• GO to JB1 See: Diagnostic Trouble Code Tests and Associated Procedures\SECTION 5: Pinpoint Tests\JB: Secondary Ignition - Pinpoint Test to check the secondary ignition system.

Is a fault indicated?
Yes

• FOLLOW Pinpoint Test direction. After repair, GO to EM40

to verify repair.

No

• GO to EM27

.

EM27 CHECK PCV SYSTEM

• GO to HG1 See: Diagnostic Trouble Code Tests and Associated Procedures\SECTION 5: Pinpoint Tests\HG: Positive Crankcase Ventilation (PCV) System - Pinpoint Test to check the PCV system.

Is a fault indicated?
Yes

• FOLLOW Pinpoint Test direction. After repair, GO to EM40

to verify repair.

No

• GO to EM28

.

EM28 CHECK BASE ENGINE

• Go to Engine System-General Information to check base engine for concerns such as intake manifold leaks, improper compression, valvetrain or camshaft damage.

Is a fault indicated?
Yes

• REPAIR as required according to diagnostic/repair information direction. After repair, GO to EM40

to verify repair.

No

• GO to EM29

.

EM29 ADDITIONAL CHECKS

• Additional checks:
• Incorrect PCV valve.

Are all checks OK?
Yes

• GO to EM45

.

No

• REPAIR as necessary. After repair, GO to EM40

to verify repair.

EM30 HIGH NOx WITH NORMAL TO LOW HC AND CO LEVELS: CHECK BASE ENGINE FOR CONCERNS SUCH AS EXCESSIVE CARBON BUILD UP IN COMBUSTION CHAMBER

• Go to the Engine System-General Information to check for base engine concerns such as excessive carbon build up in the combustion chamber.

Is a fault indicated?
Yes

• REPAIR as required according to diagnostic/repair information direction. After repair, GO to EM40

to verify repair.

No

• GO to EM31

.

EM31 ADDITIONAL CHECKS

• Additional checks:
• Transmission torque converter clutch operation.
• Cooling System concerns (such as aftermarket front fascia covering intake air, intake air system modifications).
• Engine running lean (concerns such as vacuum leaks, low fuel pressure (refer to steps starting atEM25 )).

Are all checks OK?
Yes

• GO to EM45

.

No

• REPAIR as necessary. After repair, GO to EM40

to verify repair.

EM35 EVAP SYSTEM CONCERN: PRELIMINARY CHECKS

• Analyze I/M Test Report to determine when concern is present. Attempt to verify concern.
• Make the following preliminary checks:
• Fuel filler cap (check for proper installation, physical damage or contamination).
• EVAP system lines/hoses (check for proper connections, damage or blockage).
• Fuel vapor storage canister damage.

Are all checks OK?
Yes

• GO to EM36

.

No

• REPAIR as necessary. After repair, GO to EM38

to verify repair.

EM36 PERFORM PCM QUICK TEST

• Complete PCM Quick Test to access any PCM DTCs (Refer to Section 3, Step 1: Quick Test (for Test Step procedure only)). See: QT: Step 1: PCM Quick Test

Is a fault indicated?
Yes

• FOLLOW Section 3 See: Symptom Related Diagnostic Procedures Quick Test direction. After repair, GO to EM38

to verify repair.

No

• GO to EM37

.

EM37 CHECK EVAP SYSTEM

• Go to Evaporative Emissions System.

Is a fault indicated?
Yes

• FOLLOW Pinpoint Test direction. After repair, GO to EM38

to verify repair.

No

• VERIFY test results. If OK, GO to Z1 See: Diagnostic Trouble Code Tests and Associated Procedures\SECTION 5: Pinpoint Tests\Z: Intermittent - Pinpoint Test

, or RETURN to Section 3 See: Symptom Related Diagnostic Procedures
to repair any additional symptoms. After any repair, GO to EM38
to verify repair.

EM38 EVAP SYSTEM REPAIR VERIFICATION

• Vehicle repair performed.
• Reset the keep alive memory (KAM). Refer to Section 2, Resetting The Keep Alive Memory (KAM) See: Diagnostic Trouble Code Tests and Associated Procedures\SECTION 2: Diagnostic Methods\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 2500 rpm for one minute and idle engine for two minutes.
• Rerun PCM Quick Test (refer to Section 3, Step 1: Quick Test). See: QT: Step 1: PCM Quick Test REPAIR any DTCs as directed.
• Perform the EVAP system leak test and flow check.

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

• Save any repair documentation that may be required by local/federal laws. RETURN vehicle to customer.

No

• Original concern not repaired, or another concern exists. GO to EM1

and proceed as directed.

EM40 REPAIR VERIFICATION

• Vehicle repair completed.
• Reset the keep alive memory (KAM). Refer to Section 2, Resetting The Keep Alive Memory (KAM) See: Diagnostic Trouble Code Tests and Associated Procedures\SECTION 2: Diagnostic Methods\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 2500 rpm for one minute and idle engine for two minutes.
• Rerun PCM Quick Test (refer to Section 3, Step 1: Quick Test). See: QT: Step 1: PCM Quick Test REPAIR any DTCs as directed.
• Again 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 for 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 (refer toEM3 ).

• For I/M 240 Emission Testing areas (original gas concentrations reported in Grams Per Mile):
• Refer to the beginning 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 acceptable range.

Are all gases within the acceptable range?
Yes

• SAVE any repair documentation that may be required by local/federal laws. RETURN vehicle to customer.

No

• Gas level is still high, or another gas level is above the acceptable range: GO to EM1

and proceed as directed.

EM45 CATALYST DELTA TEMPERATURE TEST

• All previous testing as indicated completed.
• Disable the AIR system, if equipped.
• Run the engine for two minutes at 2500 rpm to heat the exhaust system.
• Key OFF.
• Disconnect and ground one spark plug wire from each cylinder bank (for Coil On Plug applications, disconnect coil connector).
• Start engine and run at 1000 rpm.
• Disconnect IAC valve (maintain 1000 rpm).
• Measure the surface temperature of both the inlet and outlet of each under-body 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

• The catalytic converter(s) is operating correctly. RECONNECT spark plug

wire(s), IAC valve and AIR system (if equipped). CLEAR the DTC(s) set
during testing. VERIFY previous test results. If OK, GO to Z1 See: Diagnostic Trouble Code Tests and Associated Procedures\SECTION 5: Pinpoint Tests\Z: Intermittent - Pinpoint Test
, or RETURN to Section 3 See: Symptom Related Diagnostic Procedures to repair any additional symptoms. After any repair is completed, GO to EM40
to verify repair.

No

• For the catalytic converter(s), that had less than 28°C (50 °F)

difference, testing indicates the catalytic converter is not working.
REPEAT test step to verify results. If the temperature difference is
still less than required, REPLACE the catalytic converter. RESTORE
vehicle. GO to EM40
to verify repair.