Perform a comprehensive emissions system inspection including visual checks of exhaust components, EVAP system, catalytic converters, oxygen sensors, and OBD-II diagnostic scan for trouble codes.

Warnings

Tools required

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels if raising front of vehicle
3. Allow engine and exhaust system to cool completely if vehicle was recently driven
4. Ensure OBD-II scanner has latest software updates for 2011-2014 Ford vehicles
5. Safely raise vehicle on lift or jack stands to access undercarriage components

Procedure

1. 1

   Perform OBD-II Diagnostic Scan
   Connect OBD-II scanner to diagnostic port located below driver side dashboard. Turn ignition to ON position without starting engine. Retrieve and record all diagnostic trouble codes (DTCs), freeze frame data, and monitor status. Check readiness monitors - all monitors except EVAP and O2 sensor heater should be complete for vehicles driven regularly. Document any pending or confirmed codes.
2. 2

   Inspect Air Intake System
   Open hood and visually inspect air intake system from air filter housing to throttle body. Check air filter housing for cracks or damage. Inspect all intake tubes and boots for cracks, tears, or loose connections. Verify PCV hose connections are secure and hoses are not cracked. Check for proper sealing at mass airflow sensor connection.
3. 3

   Check EVAP System Components
   Locate and inspect EVAP canister mounted on driver side frame rail near fuel tank. Check canister for physical damage or carbon dust leakage. Inspect all EVAP hoses and lines from fuel tank to engine bay for cracks, kinks, or disconnections. Verify charcoal canister vent solenoid and purge valve connections are secure. Check fuel cap for proper sealing and damaged gasket.
4. 4

   Inspect Turbocharger and Intercooler System
   Visually inspect both turbochargers for oil leaks at turbine housings and wastegate actuators. Check charge air cooler (intercooler) and all boost pressure hoses for leaks, cracks, or oil contamination. Verify all clamps are tight on boost hoses. Inspect wastegate control solenoids and vacuum lines for damage or disconnection. Any boost leaks will affect emissions and performance.
5. 5

   Examine Exhaust Manifolds and Turbo Connections
   From underneath vehicle, inspect exhaust manifolds on both cylinder banks for cracks or leaks, particularly at turbocharger flanges. Check for exhaust staining indicating leak points. Verify all heat shields are present and securely mounted. Listen for any unusual exhaust leaks that would indicate failed gaskets.
6. 6

   Inspect Catalytic Converters
   Locate all four catalytic converters (two close-coupled cats near engine, two underfloor cats). Visually inspect for physical damage, dents, or heat discoloration indicating overheating. Check for rattling by tapping converters gently - internal substrate failure creates rattling noise. Look for signs of impact damage or road debris strikes.
7. 7

   Check Oxygen Sensors
   Inspect all four oxygen sensors (two upstream pre-cat sensors, two downstream post-cat sensors). Verify electrical connectors are fully seated and locking tabs engaged. Check sensor wiring for heat damage, chafing, or rodent damage. Ensure sensors are not physically damaged or have excessive carbon buildup at tips. Note sensor locations for correlation with any diagnostic codes.
8. 8

   Inspect Exhaust System from Cats to Tailpipe
   Follow entire exhaust system from catalytic converters to tailpipe. Check all pipe connections, flanges, and welds for leaks or corrosion. Verify exhaust hangers are intact and properly supporting system. Inspect muffler and resonator for rust-through or impact damage. Check tailpipe for excessive carbon buildup or oil residue indicating potential engine issues.
9. 9

   Verify Positive Crankcase Ventilation System
   Inspect PCV valve location in driver side valve cover. Check PCV hoses from valve covers to intake manifold for cracks or oil saturation. Verify oil separator assembly connections are secure. Remove and shake PCV valve to verify it rattles freely - stuck valve affects emissions. Check for excessive oil in intake tubes indicating PCV system malfunction.
10. 10

    Check EGR System Components
    Locate EGR valve and cooler assembly on passenger side of engine. Inspect EGR valve for carbon buildup at opening. Check EGR cooler for coolant leaks at connections. Verify vacuum lines or electrical connections to EGR valve are secure. Look for excessive carbon deposits on EGR passages indicating potential restriction.
11. 11

    Review and Document Findings
    Review all diagnostic codes and correlate with physical inspection findings. Document all issues found including code numbers, component conditions, and leak locations. Take photos of any damaged or questionable components. Clear any non-critical codes if requested and verify readiness monitors reset properly. Prepare written report of emissions system condition and any required repairs.

Reassembly

1. No disassembly required for standard emissions inspection
2. If any components were removed for closer inspection, reinstall using appropriate torque specifications
3. Ensure all electrical connectors are fully seated and locked
4. Lower vehicle from lift or jack stands safely

Verification

• Confirm all OBD-II readiness monitors show complete status (may require test drive)
• Verify no new diagnostic trouble codes have set during inspection
• Start engine and listen for any exhaust leaks audible from cabin or engine bay
• Check that MIL (check engine light) is not illuminated with key on engine running
• Provide customer with detailed report of emissions system condition and any recommended repairs

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