Charcoal Canister

This procedure covers the removal and replacement of the evaporative emission (EVAP) charcoal canister, located under the vehicle near the fuel tank on 2011-2014 Ford F-150 5.0L V8 4WD models.

Warnings

Tools required

Parts

• EVAP charcoal canister × 1 — Ford BL3Z-9D653-B or equivalent
• EVAP line O-rings (assorted) × 1 — Use OEM specification
• Canister mounting bracket (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on a level surface and apply parking brake firmly
2. Place wheel chocks behind the front wheels
3. Allow vehicle to cool completely if it has been recently driven (minimum 1 hour)
4. Open the fuel filler cap to relieve any pressure in the fuel tank, then replace it
5. Raise the rear of the vehicle using a floor jack and support securely on jack stands rated for the vehicle weight
6. Verify the vehicle is stable before working underneath

Procedure

1. 1

   Locate the charcoal canister
   Position yourself under the rear driver's side of the vehicle. The charcoal canister is mounted in a bracket frame-rail-side near the fuel tank, forward of the rear axle. It is a cylindrical black plastic component approximately 10 inches long with multiple vapor lines connected to the top.
2. 2

   Disconnect the EVAP vapor lines
   Identify all EVAP vapor lines connected to the canister (typically 3-4 connections). Use the appropriate quick disconnect tool to release each line connector. Press the tool onto the fitting and pull the line straight out. Some residual fuel vapor or liquid may be present, so have shop towels ready. Mark or photograph each line connection location for proper reassembly.
   ⚠Do not pry or twist vapor lines as this can damage the quick disconnect fittings. Use proper quick disconnect tools only.
3. 3

   Disconnect the purge line
   Locate the purge line connection on the canister (usually the line leading forward toward the engine). This may have a different style connector than the vapor lines. Press the release tab and disconnect this line. Cap or plug the open line end if debris contamination is a concern.
4. 4

   Disconnect the vent line
   Locate the vent line that runs from the canister to the vent valve (typically mounted separately on the frame). Disconnect this line using the quick disconnect tool or by releasing the spring clamp, depending on the connection type used.
5. 5

   Remove canister mounting hardware
   Remove the mounting bolts securing the canister bracket to the frame rail using a 13mm socket. There are typically two bolts holding the bracket assembly. Support the canister while removing the final bolt to prevent it from falling.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
6. 6

   Remove canister from bracket
   If replacing only the canister and not the bracket, remove the bracket bolts securing the canister to the mounting bracket using a 10mm socket. The canister is held in the bracket by a clamp assembly. Separate the canister from the bracket.
   Torque spec

   Bracket Bolts25 Nm (19 lb-ft)
7. 7

   Inspect mounting area and connections
   Clean the mounting area on the frame rail with a wire brush to remove any rust or debris. Inspect all EVAP line connections on the removed canister for damage. Check that the quick disconnect fittings on the vehicle-side lines are not cracked or damaged. Inspect the mounting bracket for cracks or damage; replace if necessary.
8. 8

   Install new canister in bracket
   If the bracket was removed from the old canister, install the new canister into the bracket assembly, ensuring it is properly seated in the mounting clamp. Install the bracket bolts finger-tight, then torque to specification.
   Torque spec

   Bracket Bolts25 Nm (19 lb-ft)
9. 9

   Mount canister assembly to frame
   Position the canister and bracket assembly in the mounting location on the frame rail. Install the mounting bolts finger-tight, ensuring the canister is properly oriented with all line ports accessible. Torque the mounting bolts to specification.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
10. 10

    Connect the vent line
    Connect the vent line to the new canister. Ensure the quick disconnect fitting clicks fully into place or the spring clamp is properly seated. Tug gently on the line to verify it is locked in position.
11. 11

    Connect the purge line
    Connect the purge line to the appropriate port on the new canister, referring to your earlier photos or marks. Push the connection in until it clicks and tug to verify it is secure.
12. 12

    Connect remaining EVAP vapor lines
    Connect all remaining EVAP vapor lines to their respective ports on the canister, using your reference photos to ensure correct routing. Push each connection in until you hear or feel a click, then tug to verify the connection is secure. Ensure no lines are kinked, pinched, or routed near hot exhaust components.
13. 13

    Verify all connections
    Perform a final visual inspection of all EVAP line connections to the canister. Verify that all quick disconnect fittings are fully seated and secure. Check that the canister mounting bolts are tight and the canister does not move when pushed. Ensure no lines are in contact with the driveshaft, exhaust, or suspension components.

Reassembly

1. Lower the vehicle from jack stands safely
2. Remove wheel chocks
3. Do not start the engine until verification steps are complete

Verification

• Start the engine and allow it to idle. Listen for any vacuum leaks or unusual hissing sounds from the EVAP system area
• With the engine running, check all canister connections for fuel vapor leaks using a visual inspection
• Use an OBD-II scanner to check for EVAP system trouble codes (P0440-P0457 range). Clear any codes that may have been set during the procedure
• Drive the vehicle through several drive cycles (city and highway) to allow the EVAP monitor to complete and verify proper system operation
• Re-check for EVAP codes after 50-100 miles of driving. The presence of codes P0441, P0455, or P0456 may indicate improper installation or a defective new canister
• Perform a visual inspection under the vehicle after the first few drives to ensure the canister remains securely mounted and no lines have shifted

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