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Discussion Starter #1
Does anyone happen to have a picture of the EVAP Purge Flow Sensor on a '96 Cougar/T-Bird with a 4.6? I am converting my '95 Cougar to run with a '96 computer, and that is the only thing I have left to figure out. sinc emy '95 does not have one (just the purge flow valve), I'm not sure how/where it sits.

Thanks
 

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Trumpeter Extraordinaire
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I haven't been able to locate a drawing/photograph of the sensor, but the following excerpt from the 1996 Cougar PC/ED manual and Service Manual may help you to locate the PF sensor. From what I read, it's somewhere along a fuel vapor hose that connects to the EVAP canister:

HW18 CHECK EVAP CANISTER PURGE VALVE STUCK OPEN CONDITION OR PF SENSOR DAMAGE

Disconnect fuel vapor hose from intake manifold at PF sensor.
Reconnect the EVAP canister purge valve (electrically).
Install a hand-held vacuum pump to intake manifold side of PF sensor.
Apply 53 kPa (16 in-Hg) of vacuum to open end of PF sensor.

Does the EVAP canister purge valve-PF sensor assembly hold vacuum for 20 seconds?

Yes
LEAVE the vacuum pump connected. GO to HW19 .

No
If PF sensor housing is cracked, REPLACE PF sensor. Otherwise, REPLACE fuel vapor hose between EVAP canister purge valve and PF sensor. If fuel vapor hose was OK, REPLACE EVAP canister purge valve. RESTORE vehicle. GO to HW42 .

HW19 CHECK HOSE BLOCKAGE - EVAP CANISTER PURGE VALVE STUCK CLOSED CONDITION

Connect scan tool.
Apply 53 kPa (16 in-Hg) of vacuum to open end of PF sensor.
Key on, engine off.
Access Output Test Mode on the scan tool to cycle EVAP canister purge valve.
Key off.

Did the EVAP canister purge valve open and vacuum reading on the vacuum pump drop (air passes freely) when commanding the output on?

Yes
REMOVE vacuum pump. GO to HW20 .

No
REMOVE the vacuum pump. REMOVE blockages in fuel vapor hose between EVAP canister purge valve and PF sensor. If OK, REPLACE EVAP canister purge valve. RESTORE vehicle. GO to HW42 .


 

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Discussion Starter #3
I actually have the same manual. The problem is Ford didn't change that picture for the 96/97 years. As far as I can tell, based on where the connector sits, the EVAP Flow sensor should be near #4 (Purge solenoid). I imagine the car will run without the flow sensor, but it will most likley throw a CE light..
 

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aaron, is that at the passenger side fender? check engine light gone after that and gas mileage goes up???
 

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Yeah thats the passengers side. I had code p1443 and from searching the forums, those two parts were the common culprit for that code. I also replaced the hoses that connect the control valve, sensor and lines since a couple were cracked and the others were soon to follow. Dunno if it will improve my gas mileage or keep the CE light off since I havent driven it any where since I replaced everything. I hope it gets rid of the CE light and better gas mileage never hurts :)
 

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Hey guys, on the last pic, is there another name for the part to the right of the purge valve because i went to autozone and told them purge flow sensor and that part did not come up under that name. i even brought it in to them and they didnt know what it was...just said its sensor. Is the purge flow sensor a part i would only be able to get from the ford dealer?
 

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Thanks, to everyone who posted or replied to any p1443 relayed problems because i found what i need...autozone didnt have this but advance auto parts does and i even called ford and they wanted to charge me 60, advance auto sells this for 20. again thanks to everyone.

If this helps anyone the part is listed under

-Bwd Canister Purge Valve
-the part number is CP509

Thats from advance auto parts.
 

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Is this what your looking for?







I snapped these while replacing the Evap Control Valve & Evap Sensor this evening.
In the bottom pic, is the purge flow sensor the black piece on the right? The gold colored piece with the Ford label on the left is the purge control valve, right? My "Service Engine Soon" light has been on and off for the past month and every time I get the code read at AutoZone it's for a fault in the EVAP system - a bad sensor or purge control valve!

Thanks,

Dennis
 

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good info. How does one remove the splash guard to get at those parts?

I can't get my splash guard completely off, or even enough to get in there with more than one arm. There is a plastic bolt or clip that will not come out when I pull on it.
 

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The inner fender liner is held on by 3 plastic push-pins and several Philips screws. The push pins come out by taking a pair of pliers and pulling the center part out, then removing the entire pin. Then, just unscrew the screws and you should be good to go! I've had my driver's-side inner liner out several times because my brake proportioning valve was leaking; I just replaced it with a good valve about 2 weeks ago. My passenger-side has never had an inner fender liner since I bought it in April (not sure what happened to it!); I just got a new one from Rock Auto this past week. I'm going to wait another week or so before I put it on because I, too, need to replace parts in my EVAP system because I'm getting the "Service Engine Soon" light for trouble with the EVAP system. I'm just going to replace the canister, purge vale AND purge sensor - I know, probably overkill. But, it'll make me feel better!

Dennis
 

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I couldn't figure those pins out no how. I pulled on them, pulled on the centers, reefed on the liner and I couldn't get those out, I even tried pulling them out with a flat head...no go.

I don't want to wreck them.
 

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Even if you do wreck them, most auto parts stores (except NAPA...never seen 'em there) will carry replacements. They're usually with all the other fasteners, and they're quite cheap.
 

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For stubborn ones I use a pair of wire cutters. Open it and put the blades on both sides of the center pin (there are spaces on both sides where it will fit underneath) and pull it out that way. Note that the wire cutters will be parallel with the pin, so you will have to use both hands, one behind the tool and the other to stabilize it.
 

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For stubborn ones I use a pair of wire cutters. Open it and put the blades on both sides of the center pin (there are spaces on both sides where it will fit underneath) and pull it out that way. Note that the wire cutters will be parallel with the pin, so you will have to use both hands, one behind the tool and the other to stabilize it.
ya i've used this technique before for other stuff like this.

I'll have to see if i get some time this weekend to get in there.
 

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Aaron K., many thanks for snapping & posting those EXCELLENT pictures of the charcoal/vapor canister, purge flow valve and purge flow sensor!! My "Service Engine Soon" light has been off and on many times over the last month or so due to a problem in the EVAP system and I was just going to replace all 3 of these parts, along with any vacuum lines necessary, to hopefully cure this issue. Those pictures are going to make that task 100 times easier!!

As soon as I finish my complete suspension rebuild tomorrow and get my alignment, I'm going to tackle this EVAP problem.

Thanks again!

Dennis
 

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In the picture above, on a 1997 Thunderbird 4.6 liter V-8, where do the 3 hoses coming off the vapor canister go to/come from? I'm particularly interested in the skinny one on the back, with the 90-degree elbow because I'm going to be replacing my canister, purge valve and sensor in the next week or so, and I'm thinking about trying to replace all the lines and hoses that are part of the EVAP system.

I'm REAL tired of my "Service Engine Soon" light being on! :(

Thanks,

Dennis
 
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