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The evaporative emission system is designed to prevent the escape of fuel vapors from the fuel system. Leaks in the system, even small ones, can allow fuel vapors to escape into the atmosphere. Government regulations require onboard testing to make sure that the evaporative (EVAP) system is functioning properly. The leak detection system tests for EVAP system leaks and blockage. It also performs self-diagnostics. During self-diagnostics, the Powertrain Control Module (PCM) first checks the Leak Detection Pump (LDP) for electrical and mechanical faults. If the first checks pass, the PCM then uses the LDP to seal the vent valve and pump air into the system to pressurize it. If a leak is present, the PCM will continue pumping the LDP to replace the air that leaks out. The PCM determines the size of the leak based on how fast/long it must pump the LDP as it tries to maintain pressure in the system. EVAP LEAK DETECTION SYSTEM COMPONENTS (FIGURE 1) Service Port : Used with special tools like the Miller Evaporative Emissions Leak Detector (EELD) to test for leaks in the system. EVAP Purge Solenoid : The PCM uses the EVAP purge solenoid to control purging of excess fuel vapors stored in the EVAP canister. It remains closed during leak testing to prevent loss of pressure. EVAP Canister : The EVAP canister stores fuel vapors from the fuel tank for purging.

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Some 2005-2006 Mustang vehicles may have a malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0456. This concern can be caused by an oversized orifice in the fuel pump. Suspect fuel pumps are in vehicles built before January 1, 2006. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Install the scan tool on the vehicle and monitor various inputs at different conditions to see if the vehicle needs to have the fuel pump replaced based on the calculation. Mustang Vapor Generation Test NOTE VEHICLE MUST MEET THE FOLLOWING CONDITIONS FOR THIS TEST: FLI% BETWEEN 15%-50% (INDICATES RIGHT SIDE FUEL TANK IS EMPTY) AND FUEL/VEHICLE TEMPS BETWEEN 70-80 ° (21- 27 ° F C). 1. Install IDS and perform Data logger function. 2. Select the following PIDs: FLI% (fuel level), FRP (fuel rail pressure), VMV # (Vapor Management Valve current), FTP voltage (Fuel tank pressure transducer output voltage), CVV # (Canister vent valve duty cycle). 3. Start engine – run for 5 minutes – turn off engine. 4. Access Jet Pump Module Connector 434 and verify sender resistance is at empty (16 ohms +/- 1 ohm). 5. Start engine, let idle for 30 seconds. 6. Check FRP to ensure fuel pressure is at 40 PSI +/- 2 PSI. 7. Close VMV to ensure a purge cycle does not take place during testing. 8. Record FTP voltage (should be at atmosphere – 2.61 volts). 9. Close CVV and monitor the elapse time. 10. Record FTP voltage after 30 seconds. 11. Open CVV and turn off engine.12. Record FTP voltage (should be the same – 2.61 volts). 13. Close CVV and monitor the elapse time. 14. Record FTP voltage after 30 seconds – open CVV. Calculate Dynamic vs. static FTP rise 15. Take reading from Step 10 (should be near 2.61) and subtract by the value in Step 8. 16. Take reading from Step 14 and subtract it by the reading in Step 12. 17. Take number from Step 16 and divide it by the number in Step 15. If the calculation is greater than a factor 3, replace the fuel pump. If the calculation is less than 3, continue with Workshop Manual diagnostics. 18. If the results from the dynamic test (KOER) are 3 times larger as the results of the static test (KOEO), the fuel pump is generating excess vapor.

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Oil Separator – Cold Climate Conditions MODEL NEW E39 5 Series, E46 3 Series, E53 X5, E60 5 Series, E83 X3, E85 Z4 with M54 Engine SITUATION Certain areas of the US experience extremely cold climate conditions during the winter months. A small number of vehicles in the above series listed have experienced problems ranging from leaking or broken valve covers to complete engine failure. CAUSE Moisture accumulating in the engine oil separator, hose to oil dipstick guide tube or the orifice in the dipstick guide tube can freeze. When this occurs, depending on the position of the internal valve, this may either cause high crankcase pressures (stuck closed) resulting in valve cover leakage/breakage or cause an oil hydro-lock condition (stuck open) which could result in engine damage. NEW CORRECTION E39 In case of a customer complaint, replace the crankcase vent valve, crankcase vent hoses and remove and clean the oil dipstick guide tube orifice. E46, E53, E60, E83 and E85 In case of a customer complaint, replace the crankcase vent valve, crankcase vent hoses and dipstick guide tube

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WARNING: Observe fire safety precautions. 1. Disconnect the NEG. battery cable and insulate. 2. Remove the fuel filler cap and draw out all fuel. NOTE: The fuel tank capacity is approx. 24 gals. (90 liters). Fuel Tank View 3. 4. 5. 6. 7. 8. 9. 10. Remove the fuel filler neck cup seal (60/1). Remove the fuel tank partition wall at the front of the trunk. Detach the fuel gauge sending unit electrical connector. Disconnect the fuel supply line (69) and the return line (70). Detach the vent valve (51). Unscrew tank fasteners (50/3) Remove the fuel tank strainer (68) and clean Throughly. Lift out the fuel tank. NOTE: If the fuel tank is being replaced transfer the stick-on packings, the soundproofing strips and the fuel gauge sending unit to the new tank (note the correct position before removing). 11. Reinstall the fuel tank in reverse manner. NOTE: a. Renew seals (70/1) and (68/1). b. c. d. e. Verify that seals (71, 72) are correctly fitted. Torque the fuel supply line (69) to approx. 20 ft. lbs. (28 Nm). Torque the fuel return line (70) to approx. 25 ft. lbs. (35 Nm). Torque the fasteners (50/3) to approx. 15.5 ft. lbs. (21 Nm). Make sure washers (50/2) are in place. f. Torque the fuel strainer to approx. 28.5 ft. lbs. (39 Nm).

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REMOVAL PROCEDURE 1. Turn OFF the ignition. CAUTION: Refer to Hoist Caution in Service Precautions . 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Bend the retaining tab for the EVAP canister vent valve. 4. Remove the valve from the bracket. 5. Disconnect the electrical connector from the EVAP canister vent valve. 6. Loosen the vent hose clamp and remove the vent hose from the EVAP vent valve. 7. Remove the EVAP canister vent valve from the vehicle. INSTALLATION PROCEDURE 1. Connect the vent hose to the EVAP canister vent valve and tighten the hose clamp. 2. Connect the electrical connector to the EVAP canister vent valve. 3. Install the EVAP canister vent valve to the bracket. 4. Bend the retaining tab for the EVAP canister vent valve. 5. Lower the vehicle