This procedure covers the removal and replacement of the evaporative emissions charcoal canister on a 2021-2024 Ford F-150 with 3.5L EcoBoost V6 engine.

Warnings

Tools required

Parts

• Charcoal canister assembly × 1 — Use OEM specification
• Evaporative system line O-rings × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks at front wheels
3. Allow engine to cool completely if recently operated
4. Disconnect negative battery cable and wait 2 minutes
5. Safely raise rear of vehicle and support on jack stands rated for vehicle weight
6. Remove spare tire if equipped for improved access to canister area

Procedure

1. 1

   Access underbody components
   Locate the charcoal canister mounted to the frame rail on the driver side, above the spare tire location. Remove any splash shields or protective covers that obstruct access to the canister using trim panel removal tools and 10mm socket. The canister is a black cylindrical component with multiple vapor lines connected.
2. 2

   Disconnect electrical connector
   Locate the canister vent valve electrical connector on top of the canister assembly. Press the locking tab and disconnect the electrical connector. Secure the connector away from the work area to prevent damage.
3. 3

   Disconnect vapor lines
   Identify all vapor lines connected to the canister (typically 3-4 connections). Using the appropriate evaporative system line disconnect tool, depress the retaining tabs and carefully disconnect each vapor line from the canister. Note the position and routing of each line for reassembly. Some residual fuel vapor may escape during disconnection.
   ⚠Fuel vapors may be released when disconnecting lines. Have shop towels ready and ensure adequate ventilation.
4. 4

   Remove bracket mounting bolts
   Using a 13mm socket, remove the two mounting bolts securing the canister bracket to the frame rail. Support the canister assembly with one hand while removing the final bolt to prevent it from falling.
   Torque spec

   Bracket Bolts23 Nm (17 lb-ft)
5. 5

   Remove canister assembly
   Carefully lower the canister assembly from the mounting bracket. Inspect the mounting bracket for damage or corrosion. If the canister is being replaced due to a fault code, inspect all vapor lines for cracks, kinks, or damage that could cause system issues.
6. 6

   Inspect vapor line fittings
   Examine all vapor line quick-connect fittings on the canister for wear or damage. Check the O-rings inside each fitting and replace with new O-rings from the service kit. Ensure the locking tabs on each fitting are intact and functional.
7. 7

   Install new canister
   Position the new or serviced charcoal canister into the mounting bracket, aligning the mounting holes. Verify the canister orientation matches the original installation with vapor connections accessible.
8. 8

   Install mounting bolts
   Install the two bracket mounting bolts and hand-tighten. Using a torque wrench, tighten the bracket bolts in a cross pattern to the specified torque of 23 Nm (17 lb-ft). Verify the canister is secure and does not move in the bracket.
   Torque spec

   Bracket Bolts23 Nm (17 lb-ft)
9. 9

   Reconnect vapor lines
   Install new O-rings on vapor line fittings if not already done. Reconnect each vapor line to the corresponding port on the canister, following the routing noted during removal. Push each line firmly into the fitting until an audible click confirms proper engagement. Gently tug on each line to verify it is locked in place.
10. 10

    Reconnect electrical connector
    Reconnect the canister vent valve electrical connector to the valve on top of the canister. Ensure the connector is fully seated and the locking tab engages properly.
11. 11

    Reinstall shields and lower vehicle
    Reinstall any splash shields or protective covers removed during access, ensuring all fasteners are properly secured. Reinstall the spare tire if removed. Carefully lower the vehicle from jack stands to the ground.

Reassembly

1. Reconnect negative battery cable
2. Verify all vapor lines are properly connected and secured
3. Ensure electrical connector is fully engaged with locking tab seated
4. Double-check all mounting hardware is torqued to specification

Verification

• Start the engine and allow it to idle for 2-3 minutes, checking for any unusual noises from the evaporative system
• Using a diagnostic scan tool, clear any stored evaporative system fault codes
• Perform an evaporative system self-test using the scan tool if available, or complete a drive cycle per Ford specifications
• Inspect canister area for any fuel vapor odors or visible leaks at connections
• Verify check engine light does not illuminate after several drive cycles
• Confirm canister vent valve operation by monitoring vent valve command PIDs with scan tool during idle

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