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Discussion Starter #1
I have been reading through the posts I could find about getting all the monitors to run. A lot of them point to the drive cycle and leave it at that. I'm having that same issue, where the Catalyst, ERG, and EVAP monitors are not completing.

The other day I checked them and I was down to just the EVAP monitor. All the others had completed. No codes pending on anything. No CEL for many months. So, I looked up the drive cycle and saw that to run the EVAP test I need to do 10 minutes of steady highway driving, 45-65 mph, steady and smooth.

Took my vehicle out on the highway and drove a couple of exits. Pulled over and tried the scan tool. Now, I had all three registering as incomplete, Catalyst, ERG, and EVAP.

Can anyone explain why would the Catalyst and ERG be testing again when the tests had just been completed and no codes were thrown or pending? And, I have not disconnected the battery in months.

These monitors are very frustrating.
 

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Discussion Starter #3
Thanks Sailor, I have looked at that. It is pretty dense reading. But looking through it again it looks as if refueling can cause the EVAP to have to start from the beginning and go through all its different phases of testing.

That is good to know, and I wouldn't be surprised if for some reason that also affects the other monitors. Not sure why but since EVAP is the slowest to run through all its tests that might be significant.

from page 19:

A check for refueling events is done at engine start. A refuel flag is set in KAM if the fuel level at start-up is at least 20% greater than fuel fill at engine-off. It stays set until the evap monitor completes Phase 0 of the test as described below. The refueling flag is used to prohibit the 0.020” idle test until the gross leak check is done during cruise conditions. This is done to prevent potential idle concerns resulting from the high fuel vapor concentrations present with a fuel cap off/gross leak condition.

Good to know that if you get all your tests run and you need an inspection Don't add any gas to the tank! And generally, don't get gas in the days before you need to go for an inspection. Do you think that could be the issue?

But, I need to do some more digging, because I don't think that is the whole story for what I am experiencing.
 

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I'm wondering if you are over thinking the situation.

Do you have a P1000 code showing when you check for codes?

That's the one for "OBDII Checks incomplete", and it's the one that needs to "clear" to pass an inspection.

All tests are on a constant cycle of repeating/monitoring, makes me wonder if that's what you are looking at. (not just done once)
 

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Discussion Starter #5
Thanks for helping me with this, Sailor. I do not have any codes, P1000 or any other, and no pending codes. I understand that tests are run and re-run, regularly monitoring the condition of the various emissions systems. But, you would think, absent a finding of a fault in a system, that the ecu would indicate that the system at the last time the test was completed was functioning properly.

Instead, I get this ambiguous result that the tests have not been completed. Let's say I am going to sell the car and I want the buyer to know that everything is working properly. If the tests are always running and never seem to be all completed, then the buyer would understandably suspect that I might have cleared a trouble code recently and the computer has not yet completed running through its tests.

So, yes, I want to see that all the tests completed. And, I believe that is what our inspection stations look for also. Otherwise, everyone would just clear their codes and go in for inspection and say, "oh you know those tests are always running."

What am I missing here?
 

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Normally only battery disconnect, other loss of keep alive memory power, or clearing codes will reset the monitors. However there is a known concern with 2003 focus see Tech service bulletin 06-7-5

Publication Date: March 27, 2006
INCOMPLETE I/M READINESS STATUS TSB 06-7-5
FORD:
2003 Focus
ISSUE
Some 2003 Focus vehicles may exhibit incomplete
inspection/maintenance (I/M) readiness status during
state inspection. Reprogram The
Powertrain Control Module

Reprogramming the pcm may fix your concern
 

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Discussion Starter #7
That's got to be it in my case. Thanks for the info foci3. I'll call the dealership this morning and see what they want to reprogram the pcm.
 

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That looks like a good possibility.

SHOULD show OK on everything that's completed since the last reset, even though the tests are always running again. I was starting to wonder if you were using some type of reader that showed that activity.
 

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Discussion Starter #9
I have an appointment for Monday morning. The dealership said it would cost between $50 and $85 to reflash to pcm.

To clarify for Sailor's point, I have an Innova scan tool and it shows not only codes that get thrown but also readiness of the individual monitors. Then it summarizes those individual monitors with one of three lights: Green, yellow, and red.

Red means there are trouble codes and you would not pass inspection. Yellow means not all the monitors have run yet. Green means all the tests have run and there are no trouble codes.

I had a lot of trouble getting to where all the codes show as having run and get the green light. But then I would drive the car and without having any trouble codes or disconnecting the battery the next time I hook up the Innova it would show several of the monitors not having completed and the yellow light. So, that has me thinking the problem is what Foci is pointing out.

I will report back after the reflash and let folks know what it cost and if it resolved this problem. Part of me thinks the reflash is a waste of money because the car runs fine, but the cost is modest and I prefer to have everything working correctly. Who knows, maybe there are some other software updates that will improve the car's performance or efficiency.
 

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I use an Innova tester when test driving cars to get monitors complete for inspection. Its easier than dealing with laptop and vcm also the Ford IDS software wont show me a fault code while running the monitor test like the handheld does.
For the EVAP monitor to complete fuel level has to be between 15% and 85%. To force the EVAP monitor to run you want to clear codes with the key on engine not running then without turning key off start engine and drive.
 

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Discussion Starter #11
A partial update to report. I took the car to the dealership. I only had one key and I figured that since I was paying to reflash the pcm I might take advantage of the opportunity to get a second key.

It turns out that A) Coding a new key is a different program from reflashing the pcm, but B) You cannot reflash the pcm without two keys!

I went ahead and bought a new key ($40 !) and they programmed the keys and reflashed the pcm for another $80.

I have to drive a bit more to complete running the ERG and EVAP monitors and then I will update again to let folks know if the reflash fixed the problem and the Monitors show completion and hold that state.
 

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"Coding a new key is a different program from reflashing the pcm" thit is true a 10 minute security access require to program key when you have less than 2
"You cannot reflash the pcm without two keys" This is not true. You cannot install a new pcm with one key but you can reprogram with only one key Do it every day.
 

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The total price you paid doesn't seem bad at all. I would have guessed it would be higher.

Most people recommend you have 3 PATS keys; in case you lose one. You can buy additional PATS keys online ($10 to 15), have em cut at your local hardware store, and program them yourself at home. The programming process is crazy-Easy. Link is a video that shows you how->
https://www.youtube.com/watch?v=0oJXWE_SKvM
 

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That's a good Deal!

Cost was the same as is usually seen for a replacement key alone when you only have one.

As Marde mentioned, it's cheaper now to make a spare to have three avail..
 

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Discussion Starter #15
I just want to do a final follow-up on this thread for future readers. The pcm reflash did indeed solve the I/M monitors problem that I was having on my 2003 ZX3.

Since the reflash, whenever I plug in my Innova scan tool it shows all monitors have run and I get the green light on my scan tool. This is Innova's way to indicate that all monitors have run and no trouble codes have been generated.

In my case a reflash was the correct solution and solved the problem. If anyone is curious, as I was, I did not notice any additional benefits as far as performance or fuel economy resulting from the reflash. Of course, I didn't have any real problem with performance or fuel consumption to begin with, but I was still curious if the reflash included any upgrades that would improve performance.
 

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I just want to do a final follow-up on this thread for future readers. The pcm reflash did indeed solve the I/M monitors problem that I was having on my 2003 ZX3.

Since the reflash, whenever I plug in my Innova scan tool it shows all monitors have run and I get the green light on my scan tool. This is Innova's way to indicate that all monitors have run and no trouble codes have been generated.

In my case a reflash was the correct solution and solved the problem. If anyone is curious, as I was, I did not notice any additional benefits as far as performance or fuel economy resulting from the reflash. Of course, I didn't have any real problem with performance or fuel consumption to begin with, but I was still curious if the reflash included any upgrades that would improve performance.
Paul,
Thank you for that update and glad it all worked out for you.

Paul
 
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